Bundled printed sheets

ABSTRACT

The present disclosure provides bundled printed sheet articles, an apparatus for the manufacture of bundled printed sheet articles, and methods of making and using the bundled printed sheet articles.

RELATED APPLICATIONS

This patent application relates to copending provisional applicationU.S. Ser. No. 60/475,935, filed Jun. 3, 2003, entitled “CUT-AND-STACKLABEL PRODUCTION SYSTEM AND METHOD,” the disclosure of which isincorporated herein by reference in its entirety.

BACKGROUND

There exists a need for improved bundled printed sheet articles. Therealso exists a need for an effective apparatus for the manufacture ofbundled printed sheet articles. There also exists a need for improvedmethods of making and methods of use of bundled printed sheet articles.

SUMMARY

The present disclosure is directed to bundled printed sheet articles, toan apparatus for their manufacture, and to methods of making and usingthe articles.

The present disclosure, in embodiments, provides a bundle of printedsheets, comprising:

-   -   a plurality of printed sheets in a stack;    -   a band around the stack; and    -   an optional overwrapper on the banded stack,    -   each printed sheet having a narrow cut-to-print registration        variance, and    -   each printed sheet having the same length and width dimensions        as the other printed sheets in the stack to within a narrow        variance.

The present disclosure, in embodiments, also provides an apparatus formaking bundled printed sheets, the apparatus comprising:

-   -   a printable web;    -   a print module to print on the printable web;    -   a cutter module to cut the printed web into a stream of printed        sheets;    -   a collator to collate each stream of printed sheets into a        registered stack;    -   a conveyor module to convey each registered stack into a stack        stream; and    -   a packaging module to package each registered stack in the stack        stream into a package of bundled printed sheets.

The present disclosure, in embodiments, also provides a method of makingbundled printed sheets, comprising:

-   -   printing on a printable web;    -   cutting the printed web into a stream of printed sheets and a        waste matrix;    -   collating each stream of printed sheets into a registered stack;    -   conveying each registered stack into a stack stream; and    -   packaging each registered stack in the stack stream to form a        bundle of printed sheets.

The present disclosure, in embodiments, also provides a method of makingbundled printed sheets, comprising:

-   -   providing single-sheets;    -   optionally printing on the single-sheets with a print engine;    -   cutting each single-sheet into a stream of cut printed sheets        and a waste matrix;    -   collating each stream of cut-printed sheets into a registered        stack;    -   conveying each registered stack into a stack stream; and    -   packaging each registered stack in the stack stream into a        bundle of printed sheets.

The present disclosure, in embodiments, also provides a method ofaffixing printed sheets to articles.

In embodiments of the present disclosure, there is also provided a stackor bundle of printed sheets in a label applicator machine.

The present disclosure, in embodiments, also provides an article havinga printed sheet attached thereto, the printed sheet being obtained fromunpackaging a bundle of printed sheets of the disclosure.

The present disclosure, in embodiments, also provides a printing systemfor making and packaging bundles of precision printed and cut sheets.

These and other embodiments of the present disclosure will becomeapparent after a review of the following detailed description of thedisclosed embodiments and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of a web-based apparatus for making the bundledprinted sheet articles, in embodiments of the present disclosure.

FIG. 2 is a schematic of a sheet-fed based apparatus for making thebundled printed sheet articles, in embodiments of the presentdisclosure.

FIG. 3 illustrates a block diagram overview of a web-based process ofFIG. 1 for preparing bundle printed sheets, in embodiments of thepresent disclosure.

FIG. 4A illustrates a perspective of a portion of a web-based apparatusfor preparing bundle printed sheets, in embodiments of the presentdisclosure.

FIG. 4B illustrates a section view of a cutter module in a web-basedapparatus for preparing bundle printed sheets, in embodiments of thepresent disclosure.

FIG. 5 illustrates a block diagram overview of a sheet-fed based processof FIG. 2 for preparing bundle printed sheets, in embodiments of thepresent disclosure.

FIGS. 6A and 6B illustrate alternative configurations of a collatormodule and a conveyor module of an apparatus for preparing bundledprinted sheets, in embodiments of the present disclosure.

FIGS. 7A and 7B illustrate alternative conveyor modules of an apparatusfor preparing bundled printed sheets, in embodiments of the presentdisclosure.

FIGS. 8A-8D illustrate examples of cut patterns for forming cut printedsheets, in embodiments of the present disclosure.

FIGS. 9A and 9B illustrate bundled printed sheets, in embodiments of thepresent disclosure.

FIGS. 9C and 9D illustrate other examples of bundled of printed sheetshaving alternative stack or bundle geometries, in embodiments of thepresent disclosure.

DETAILED DESCRIPTION

To promote an understanding of the principles of the present disclosure,descriptions of specific embodiments of the disclosure follow andspecific language is used to describe the specific embodiments. It willnevertheless be understood that no limitation of the scope of thedisclosure is intended by the use of specific language. Alterations,further modifications, and such further applications of the principlesof the present disclosure are contemplated as would normally occur toone ordinarily skilled in the art to which the disclosure pertains.

In embodiments, the present disclosure is directed to bundled printedsheet articles. The bundled printed sheet articles can have, inembodiments, for example high print quality, high length and widthdimensional attributes, and high print-to-cut registration attributes.The present disclosure, in embodiments, is also directed to an apparatusfor making the bundled printed sheet articles. The present disclosure,in embodiments, is also directed to methods of making and to methods ofusing the bundled printed sheet articles.

Definitions

“Substrate” refers to a web-fed or a sheet-fed material from which cutprinted sheets are prepared by the process of the present disclosure.

“Module” refers to a component or subassembly of the apparatus of thedisclosure which can accomplish a defined function or operation, such asa print module for printing, a coater module for coating, a cuttermodule for cutting, a collator module for collating, a conveyor modulefor conveying, and a packaging module for packaging. The modules of thedisclosure can be adapted to be serially (i.e., modules linked inseries) or multiply (e.g., one or more coating modules) integrated withother modules of the apparatus. The modules of the disclosure preferablycan be readily modified or serviced in place, or additionally oralternatively, preferably readily replaced or interchanged with asimilar or different module (e.g., a web-based four color print moduleinterchanged with a sheet-fed xerographic color print module).

“Cut-to-print registration,” “cut-edges to print registration,” “printregistration to cut edges,” “print-to-cut registration” or like phasesrefer the position of a printed image with respect to its exact, ideal,or desired cut-out pattern of the printed image compared to the actualor achieved cut-out pattern of the printed image in web-feed orsheet-feed embodiments of the present disclosure.

“Print-to-print registration” refers the position of a printed imagewith respect to adjacent printed images on a moving web.

“Angle-cut,” “angle cutting,” and like terms refer to cutting of printedsheets from the web or from fed-sheets at an angle other than square tothe process direction, for example, where at least the edges of theprinted sheets approximately parallel to the process direction are cutat a slight angle to parallel. Alternatively, “angle cutting” printedsheets from the web- or from fed-sheets can be accomplished where atleast the lead and trail edges of the printed sheet are normal(perpendicular) to the process direction are cut at a slight angle tonormal. In preferred embodiments the printed sheets preferably areangle-cut on both parallel edges and the lead and trail edges.

“Sheet stream” refers to a continuous or semi-continuous intermediatetransport or flow of cut printed sheets from the cutter to furtherprocessing. A sheet stream originates upon cutting the web or sheet-fedsubstrate and ceases when the individual cut sheets of a stream arereceived by a collator and collated into a stack. Additionally, a sheetstream is formed from successive cutting events in a specific referencelocation on the web or the same region of successively fed-sheets, whichproduce a series of cut printed sheets.

“Collate,” “collated,” “collation,” “collating,” and like terms refer tocollecting a portion of the cut printed sheets from each sheet stream toform an individual stack of cut printed sheets having uniform geometryor having unitary three-dimensional ordering.

“Stack” refers to a plurality of unsupported cut printed sheets piledatop one another and having substantially the same orientation. “Stack”also refers to a loose but ordered ream of cut printed sheets of thedisclosure.

“Stack stream” refers to a continuous or semi-continuous transport orflow of registered stacks from the collator to further processing.

“Bundle” refers to a stack of cut printed sheets having a securing band,a protective overwrapper, a partial overwrapper, or combinationsthereof.

“Banding,” “banded,” and like terms, refer to surrounding at least aportion of a registered stack with a band.

“High bundle-to-bundle uniformity” refers to such aspects as appearanceuniformity, dimensional uniformity, performance or use uniformity, andlike uniformity aspects, between or among bundles produced in the sameprint job. Additionally or alternatively, high bundle-to-bundleuniformity refers to low bundle-to-bundle variability.

“Print engine” refers generally to any print system or markingtechnology that is compatible with image or print formation aspects ofthe present disclosure, for example, as illustrated herein; “printengine” is not limited to, for example, digital print technologies.

As used herein the singular forms “a,” “an,” and “the” include pluralreferents unless the content clearly dictates otherwise. Thus, forexample, reference to a product or article containing “a sheet” caninclude one or more sheets, or reference to a sheet printed with “anink” can include one or more inks.

“About” modifying, for example, the quantity, dimension, duration, orlike metrics of an article, apparatus, process, and like values, andranges thereof, employed in the disclosure, refers to expectedvariations in the numerical quantity that can occur, for example,through typical measuring and handling procedures used to describe orquantitate aspects of the disclosure; through inadvertent error in theseprocedures; and through differences in the manufacture, source,environmental sensitivity, or purity of the materials used in thearticles, apparatus, or processes of the disclosure.

“Consisting essentially of” refers to the recited items in the claim andincludes unrecited items or aspects that do not materially affect thebasic and novel properties of the articles, apparatus, or processes ofthe disclosure. Aspects or items that can materially affect the basicproperties of the articles, apparatus, or processes of the presentdisclosure are those which impart undesirable characteristics or imposeundesirable results thereon, for example, slow drying or non-curable inkor coating formulations, web- or sheet-stock which is dimensionallyunstable or environmentally highly variable, cutting or collating whichis highly imprecise or highly variable, or packaging materials which arenot robust to the rigors of transport, handling, storage, or industrialuse.

Referring to the figures, FIG. 1 illustrates a schematic overview of anapparatus for making the bundled printed sheet articles, in embodimentsof the present disclosure. The apparatus or production system 10 is anautomated continuous web-based system for high volume production ofindividual printed sheets from the web, free standing or supportedstacks of the printed sheets, and packaged stacks of the printed sheets,that is a plurality of bundles of printed sheets.

The web can be printed or imaged to form a plurality of substantiallyidentical printed regions on the web, which printed web can be, forexample, subsequently precision cut into individual printed sheets. Theindividual printed sheets can be stacked. The stacks can be bundled, andthe bundles can be boxed for shipping or storage. The foregoingillustrative steps can be accomplished continuously and withoutinterruption. Other steps, such as a finish coating, anti-statictreatment, and like steps, can optionally be incorporated into theapparatus and process of the present disclosure and illustrated herein.The apparatus and process of the present disclosure provide for thecontinuous high volume and high quality manufacture of bundled printedsheets. FIG. 1 shows various individually numbered modules, stations, orcomponents only by way of example and to illustrate various preferredembodiments.

Substrate Staging (Web- or Sheet-Fed)

Substrate feed module or station 11 preferably can be a web-stockloading area where, for example, unprinted paper, plastic film, or othersuitable sheet stock is fed into the system using supply rolls andunroll festoons to control tension and other relevant parameters, and topermit adding additional web rolls so as to enable continuous operationover extended periods and without interruption or shut-down. Such webloading and change-over equipment is commercially available from, forexample, Keene Technology, Inc., Beloit, Ill.; and Martin Automatic,Inc., Rockford, Ill. A preferred component for this station is the modelZG 2650-10 shaftless butt splicer from Keene Technology, Inc.

Substrate Marking and Inspection

Printing module 12 or station can be, for example, a web offset printengine or like printing equipment, which module images or prints desiredpatterns or marks on one or both sides of the web.

In embodiments printing on the web or on fed-sheets (discussed in FIG. 2below) can comprise any suitable print method, including for example,offset, lithography, flexography, gravure, non-impact printing methods,electrophotography, or combinations thereof. Offset printing typicallyincludes an intermediate image receiver such as a printing plate.Lithography typically includes a printing member having ink receptiveregions and ink rejecting regions, which opposite regions result inimage and non-image regions on the printing member. Gravure printingmethods typically include a printing member having a metal cylinderetched with numerous tiny wells that hold and release ink. Non-impactprinting methods can use, for example, lasers as in laserography, ionsas in ionography, ink jet as in thermal ink jet or bubble ink jet,thermal transfer imaging, and like methods and devices to form ortransfer images on or to a receiver, such as a continuous web or asingle sheet receiver. Electrophotographic printing methods include, butare not limited to, for example, xerography (e.g., from Xerox Corp),liquid immersion development (LID, e.g., from Indigo), ionography (e.g.,from Delphax), and like methods.

In embodiments, the print module can comprise a single print engine, ortwo or more print engines, and which print engines can have the same ordifferent marking technology or capabilities. Thus, for example, a firstprint engine, such as an offset print engine, can print constant imageinformation, such as CMYK four-color image and text, and a second printengine, such as an ink jet or xerographic print engine, can printvariable image information, such as custom color, specialty graphics,production information, customer information, lot or serial numbers,expiration dates, or like image or indicia information. It is understoodthat two or more different print engines can be configured to print onthe same side of the substrate, opposites sides of the substrate, orboth.

The printing and subsequent processing of the printed images, such ascutting and stacking, is preferably monitored and performed with atleast one, and preferably four or more, different inspection systems,such as inspection station 25. One system, a video print inspectionsystem, can aid a system operator or automated controller in theinspection of print quality. Another system, a print registrationcontrol, can check and automatically correct the print register. Yetanother system, a closed-loop color control, can analyze and adjust inkdensity according to the pre-defined desired print specifications. Stillanother system, for example, a video die-cut inspection system, can aidthe operator in the inspection of web- or fed-sheet cut-quality. Theorder of the inspection stations may be rearranged. The use of each ofthese specific inspections is not required, but the use of all of themcan be preferred in embodiments.

The apparatus and method can further include monitoring the registrationof the printing to the cutting. In embodiments, monitoring theregistration of the printing to the cutting enables, for example, theelimination of a characteristic telltale white strip or unprinted areaartifacts from the printed sheets.

An ability to accurately measure or monitor basic aspects, such as theabove mentioned product, process, and operational aspects of theapparatus, is frequently facilitated by a pre-defined product or processtarget specification for quality control or quality assurance. Suchtarget specifications and achievement of the target specifications canprovide useful documented “proofs” of the process leading to theproduct.

Measuring or monitoring aspects of the printing and packaging system,such as mentioned above, can be accomplished, for example, on-line,off-line, or combinations thereof. The measurements are preferablyaccomplished on-line using process automation tools, for example,positional sensors, video microscopy or magnification, in conjunctionwith analytic or diagnostic software, for observing and maintainingprint, image, color fidelity, cut-to-print registration, print-to-printregistration, reproducibility, and like quality parameters.

In embodiments, monitoring the registration of the print-to-cut can beaccomplished by continuously detecting a reference mark on the webmatrix region prior to cutting, and continuously adjusting, as needed,the web relative to the cutter, the cutter relative to the web or both,(e.g., using web guides, web compensator rollers, and like adjustablecomponents), to achieve a predetermined alignment of the cutter relativeto printed items on the printed web. The aforementioned adjustment ofthe cutter can include, for example, controllably varying the speed ofthe web, controllably varying the position of the web, continuouslyadjusting the die-cutter (e.g., circumferentially, laterally, or both)or combinations thereof. Here “predetermined alignment” refers to properalignment needed to achieve target print-to-print and cut-to-printregistration specifications. Continuous registration and likeadjustments can provide a number of advantages including avoidingproblems associated with cutters, such as a guillotine cutter, forexample, unreliable or unpredictable dimensional consistency anduniformity, alignment, registration, and like issues. Thus, the presentprocess and apparatus can cut each printed sheet individually. Thepresent process and apparatus can also cut a plurality of sheetsindividually and at the same time.

The following documents disclose or illustrate suitable command andcontrol equipment, monitoring or measurement equipment, or relatedcomponents or features which, in embodiments, can be adapted for usein-part in the present disclosure without departing from inventiveaspects of the present disclosure: U.S. Pat. No. 5,460,359, discloses abinding apparatus for binding sheets of cut paper printed by a printingmachine including a control system; U.S. Pat. No. 4,891,681, discloses ahard copy apparatus for producing center fastened sheet sets includingtrapezoidal stacks for folded binding, and a control system; U.S. Pat.No. 4,785,731, discloses a bundle count verifier (e.g., for newspaperbundles); U.S. Pat. No. 4,727,803, discloses a conveyor device with anarticle lifting unit; U.S. Pat. No. 4,566,244, discloses a paper sheetgrip and transfer apparatus for a counting and half-wrapping device, seealso disclosed therein Japanese Laid-Open Patent Specification No.57-8616 (transport of paper sheets) and Japanese Laid-Open Utility ModelSpecification No. 50-98791 (transfer a pile of paper sheets on a beltwithout holding the sheets on the belt); and U.S. Pat. No. 4,424,660,discloses an apparatus for binding paper sheets stacked within a hopperinto bundles each consisting of a predetermined number of paper sheetsincluding a method of sheet transport, for example, sheets sandwichedbetween belts.

Substrate Coating, Conditioning, or Treatment

The method of making can further comprise optionally applying a coatingto the first face, the second face, or both faces of the printed web.The coating can be applied to the printed side of the web, the unprintedside of the web, or both the unprinted side of the web and the printedside of the web, depending for example, on the properties desired forthe printed sheets and the bundled printed sheets. The coating can be,for example, a varnish coat, a gloss coat, a clear coat, a seal coat, anantistatic treatment, and like coatings, or combinations thereof.

Optional coating, conditioning, or treatment modules 13 or stations caninclude, for example, optional in-line coaters 13 a-c, which can apply,for example, a functional coating to one or both sides of the web, suchas gloss coat or varnish coat. In embodiments, the web after leaving thecoater 13 a can, if desired, be diverted by re-routing to extend theweb's path and to permit satisfactory leveling or drying of the appliedfunctional coating before further processing steps are accomplished. Oneor more additional in-line coating units 13 b-c (not shown) can apply asecond or a third functional coating to one or both sides of the web,such as an antistatic or static-preventing coat, a silicone basedantistatic coating, and like coatings, or combinations thereof, or otherperformance or appearance enhancing chemical coats. Antistaticcompounds, such as quaternary ammonium salts, and antistaticformulations are known and are commercially available. Coating the web,for example, with varnish or similar materials, can be used to protector to enhance the appearance of the printed product, such as labels, insome printing embodiments. If foil or laminate print technologies areused, coating with varnish may not be necessary. The coating module maybe integrated into the print module, and therefore may be provided by acommercial manufacturer. Preferred equipment for use in modules 12 and13, in embodiments, can be, for example, the model QUANTUM 1250CM presscommercially available from Sanden Machine Ltd., of Cambridge, Ontario,Canada. Equipment, processes, and control systems for coating webmaterials are generally disclosed, for example, in U.S. Pat. No.4,886,680. In embodiments, optional interstation web chilling modules(not shown) can be employed, for example, after or between each printtower or print station to, for example, remove excess heat, facilitatecure or drying of the printed or coated web, promote proper finishing orsurface textures, and like enhancements, such as in a multi-color (e.g.,4 to 15 print towers) web offset press using UV curable inks.

The method of making can further include chilling the printed web. Anoptional web chiller 13 d or chilling mechanism, such as one or morerefrigerated rollers, coolant chilled rollers, cool conditioned air, orlike chilling mechanism, which can be non-contact with the web orpreferably in-contact with the web, can be employed to cool and therebystabilize the post-print or post-coat web product and can provideimproved registration prior to cutting the web into individual printedsheets.

The apparatus and method can also further include a web guide system forweb substrate regulation. An optional web guide system 13 e can beemployed in embodiments for substrate regulation and to provide improvedregistration of the printed web presented to the cutting module, such asa die-cutter.

In embodiments, an optional corona charger or like charging devices,such as charger 23, or discharging devices, such as antistatic bar orstatic eliminator 26, can be use to electrostatically condition or treatthe web before or after the print module. Charging the web can, forexample, make the web, such as a plastic film, composite, orlaminate-based web, more receptive than otherwise to inks, coatings, orlike treatments. Discharging or removing static from the web or from theresulting cut printed sheets can, for example, facilitate sheettransport and stacking by reducing or eliminating sheet charging,like-charge repulsion, and like problems.

Substrate Cutting

After the web has been printed and optionally conditioned or surfacetreated, the web is guided to a cutter module 14. The cutter module caninclude, for example, a rotary die-cutter, a flat-bed die-cutter, aslit-and-gap cutter, a slit-and-but cutter, a guillotine cutter, andlike cutters, or combinations thereof A preferred cutter module caninclude, for example, an in-line rotary die-cutting system, whichdie-cutter can cut individual printed sheets from the printed web tocreate a corresponding continuous sheet stream and a continuous cut-outwaste stream or waste matrix.

In embodiments where two or more die cutters are employed, a first diecutter can be adapted to cut customized details or features from theincipient (not-yet-cut) printed sheets, such as notches, holes, hang tagapertures, concave curves, convex curves, or both, and like geometric ordesign details, and without severing or separating the printed sheetfrom the web or fed-sheet. A second die cutter can be adapted to furthercut the printed sheets, or completely cut-out individual printed sheetsfrom the substrate. In embodiments the cutter module can optionally beadapted so that a die cutter cuts the substrate to the desired anddefined dimensions for each printed sheet except for a small fiberregion or umbilical thread, for example, of about 10 to about 1,000microns, and preferably about 100 to about 200 microns, between thesubstrate and the sheet, preferably at the lead and trailing edges ofthe sheet and the substrate, which can momentarily retain the materialconnection and force continuity between the nearly completely cutprinted sheet, in-line nearest neighbor printed sheets, the movingsubstrate, or combinations thereof. An optional edger or slicer cansubsequently “burst” the umbilical thread at a more favorable locationdown stream. An optional debris collector, such as a vacuum line orvacuum manifold, can be situated in close proximity, such as from about1 centimeter to about 100 centimeters to remove potentiallyobjectionable dust and like debris generated from the burstingoperation.

In embodiments, a continuous sheet stream is preferred for productivityand economy. However, occasionally the bundled printed sheet productionprocess of the disclosure may need to be briefly suspended to make, forexample, change-overs, adjustments, repairs, and like maintenance orproduction optimization. The process and apparatus of the presentdisclosure can be adapted with, for example, controls and qualityspecifications, to permit as-needed temporary suspension or interruptionof production without jeopardizing an entire print job. In this sense asheet stream can have a semi-continuous character when, for example, itsflow is temporarily interrupted.

In embodiments, the cutter module can include a static eliminator. Thestatic eliminator can facilitate separation of cut sheets and wastematrix, and prevent the cut sheets from following or adhering to thematrix, the cutter, other sheets, or to the sheet transporter. Methodsof static charge or frictional charge suppression or elimination, foruse in place of or in conjunction with humidity control, can include,for example, a conductive or non-conductive disturber brush, an airionizer such as a charge corotron, a de-ionizer, and like articles ordevices. Other methods of static charge or frictional charge suppressionor elimination, for use in place of or in conjunction with humiditycontrol, can include, for example, applying an anti-static coating orlike surface treatment, where for example one or both side of the web orfed-sheets are treated before or after printing.

In-line die-cutting of a printed web to produce individual cut printedsheets, such as printed labels, as in the present disclosure saves timeand lowers cost compared to processing the cut printed sheets or labelsindividually at various stages. In-line die-cutting can also produce anexact or substantially exact duplication of the cut features in each andevery printed sheet produced. In contrast, cutting labels with, forexample, a guillotine cutter, can often be prone to operator error ormechanical error (e.g., attributable to cumulative machine wear) whichcan lead to greater variation and lower quality in the finished product.An in-line die-cutting system can provide ideal duplication of specifiedproduct dimensions as well as accurate print-to-cut registration. Ifdesired, a cutting module having a die-cutter can be preferablyintegrated into a print module similar to the abovementioned integratedcoating module. Rotary die-cutting equipment, such as rotary dies andflexible dies, print cylinders, and other rotary tooling for precisiondie-cutting, is commercially available from, for example, Rotometrics ofEureka, Mo.; and Bemal Inc., of Rochester Hills, Mich. Various otherwide format cutters and related in-line finishing equipment iscommercially available from, for example, Advance Graphic Equipment(www.advancegraphicsequip.com).

In embodiments, the apparatus and method of the disclosure whichemploys, for example, a die-cutter, can provide cut printed sheetshaving a print-to-cut registration, that is print registration to cutedges variance, for example, from less than or equal to about plus orminus 0.0625 inches ({fraction (1/16)}^(th) inch), more preferably fromless than or equal to about plus or minus 0.046875 inches ({fraction(3/64)}^(th) inch), even more preferably from less than or equal toabout plus or minus 0.03125 inches ({fraction (1/32)}^(nd) inch), andeven still more preferably less than or equal to about plus or minus0.015625 inches ({fraction (1/64)}^(th) inch). In embodiments, theapparatus and method of the disclosure which employ, for example, arotary die-cutter, can routinely provide cut printed sheets having aprint registration to cut edges variance, for example, less than orequal to about plus or minus 0.03 inches.

In embodiments, the apparatus and method of the disclosure which employ,for example, a rotary die-cutter, can provide cut printed sheets suchthat each sheet has substantially the same length and width dimensionsas substantially all the other cut printed sheets produced in the job,for example, to within a variance of less than or equal to about 0.010inches ({fraction (1/100)}^(th) inch), more preferably less than orequal to about 0.0075 inches ({fraction (1/133)}^(rd) inch), even morepreferably less than or equal to about 0.00666 inches ({fraction(1/150)}^(th) inch), and even still more preferably less than or equalto about 0.005 inches ({fraction (1/200)}^(th) inch).

Preferences for the above mentioned narrower print-to-cut registrationvariance and narrower length and width dimensional variance, will bereadily appreciated by one of ordinary skill in the art, and caninclude, for example, higher quality printed sheets, higher stack andbundle uniformity and quality, greater latitude for print layout,artwork, sheet design, and sheet geometry, greater intermediate-user andend-user customer acceptance, greater reliability in methods ofapplication of the printed sheets to articles, greater ease-of-handlingand ease-of-use, and like intrinsic and extrinsic benefits.

In embodiments, the apparatus and method of the disclosure which employ,for example, a rotary die-cutter can provide cut printed sheets and intheir corresponding bundled printed sheets where each cut printed sheetproduced can have a cut-to-print registration variance of, for example,from less than or equal to about 0.0625 inches, and the same length andwidth dimensions as the other printed sheets in the stack to within avariance of less than or equal to about 0.010 inches. In embodiments,the apparatus and method of the disclosure which employ, for example, arotary die-cutter can provide cut printed sheets and correspondingbundled printed sheets where each cut printed sheet produced can haveboth a cut-to-print registration variance of, for example, from lessthan or equal to about 0.046875 inches, and the same length and widthdimensions as the other printed sheets in the stack to within a varianceof less than or equal to about 0.0075 inches. In embodiments, theapparatus and method of the disclosure which employ, for example, arotary die-cutter can provide cut printed sheets where each cut printedsheet produced has both a cut-to-print registration variance of, forexample, from less than or equal to about 0.03 inches, and substantiallythe same length and width dimensions, for example, to within a varianceof less than or equal to about 0.005 inches, as substantially all theother cut printed sheets in a job, for example, over a 24 to 48 hourperiod, or more, of continuous production or apparatus operation. Inother like recitations of cut-to-print registration variance, lengthdimensional variance, and width dimensional variance, it will beunderstood to include “less than or equal to” if not explicitlyindicated. It will also be understood that variances can be determinedby any suitable measurement methods, for example, video microscopy,microscopy with a calibrated vernier or reference standard, amicrometer, and like measurement methods.

In embodiments each cutting event of the printed web can beaccomplished, for example, widthwise across the web process direction orin a variety of alternative schemes, for example, as disclosed herein.Alternatively or additionally, the cutting can be accomplishedsimultaneously or semi-simultaneously with a die-cutter. The die-cuttercan cut printed sheets from the web in a variety of ways, such as webprinted items which are, for example, aligned adjacent sheets, staggeredadjacent sheets, angle-cut adjacent sheets, or combinations thereof. Inembodiments, die-cutting of printed sheets can be accomplishedsimultaneously, having stagger between or among adjacent latent orincipient streams of printed sheets. In preferred embodiments,die-cutting can be accomplished with angle-cut of one or more of theedges of the printed sheets. Angle-cutting the web- or fed-sheetsproduces sheets which can be, for example, square shaped or rectangularshaped and can optionally have square corners of about 90 degrees. Thesesheets are cut by a die that has a minor skew angle or orientationaloff-set of the cut edges from parallel, perpendicular, or both, relativeto the web's process direction edges, so as to allow the rotary diecutter to achieve cuts which provide more shear-type cut forces andminimizes or eliminates “bounce” or recoil associated with simultaneouscutting of like pieces from the moving web at high speeds. Thus, inangle-cut die-cutting the die-cut blade is preferably slightly skewedby, for example, about one half of a degree so that the lead edge ofeach die-cutting blade provides web cross-cut action from a point andproceeds in a line rather than a perpendicular “all-at-once” cut normalto the edges of the web or the fed-sheet.

In embodiments, die-cutting the printed web can be configured tocontinuously produce a stream of printed sheets from a correspondingwidth of the printed web. Die-cutting is preferably accomplished in acontinuous fashion, for example, without hesitation or interruption inthe speed or movement of the printed web or printed fed-sheets. Thepreference for continuously die-cutting is evident from, for example,measured economic efficiencies, product throughput, and minimized orminimal operator intervention. In embodiments, each die-cutting ordie-cut event can be accomplished in one of several alternative schemesor variations on the schemes and combinations thereof, for example,“simultaneous” die-cutting wherein the lead edge of each sheet of anarray of printed pieces on an advancing web or a fed-sheet substrate isfirst cut by a suitably adjusted and configured die-cutter. Thedie-cutting continues to cut out the printed pieces from the web or thefed-sheets arriving from an upstream process direction to generateindividual printed sheets or an array of individual printed sheetsacross the process direction. In embodiments of the presently disclosedmethods of making bundled printed sheets, each cutting event canproduce, for example, from 1 to about 80 of individually cut and printedsheets width-wise across the web process direction, depending on forexample, the desired (x- and y-) dimensions of the resulting cut printedsheets and their bundles.

In embodiments, the cutter module can be configured to have one or morecutters, such as two or more rotary die-cutters in series, for cuttingthe printed web or printed fed-sheets, for example, where it isnecessary or convenient to accomplish multiple cuts or special-effectcuts on or within a single sheet, such as “doughnut hole” or “window”cut-outs within a sheet, notches on the edge of a sheet, and like cuts,or combinations thereof. Alternatively, a single cutter, such as arotary die-cutter having an appropriately configured die, can oftenaccomplish many, if not most, examples of multiple cuts orspecial-effect cuts on each sheet with a single die-cut pass orimpression.

Matrix Removal, Sheet Conveyance, and Sheet Collation

The abovementioned waste matrix or residual web skeleton can beoptionally continuously removed and discarded with a waste matrixmanagement module 15, for example, with a vacuum take-off or a windabletake-up reel. A vacuum take-off is generally preferred since it canprovide higher capacity waste matrix removal, continuous operation, andenhanced safety and handling convenience by directing the waste to anarea away from production. After the web is cut the transport integrityof the original web no longer exists thus the resulting cut printedsheets preferably need to be individually, continuously, and orderlytransported to a sheet stacker in the collator module 16 in one or morecut printed sheet product streams. Each cut sheet product stream can betransported to the sheet stacker or “batch stacker” with a sheetdelivery system employing, for example, opposing belts, rollers, vacuumtransporters, and like apparatus, or combinations thereof. Examples ofpreferred suppliers of commercially available equipment for the wastematrix removal module include Quickdraft of Canton, Ohio; and individualsheet delivery or transport systems and sheet stackers include,Gannicott, Ltd. of Toronto, Ontario, Canada, see also U.S. Pat. No.4,102,253.

In embodiments, the collating can be accomplished with a sheet transportand stacking machine which has been suitably modified to receive andcollate multiple individual cut printed sheets of one or more sheetstreams at the same time. In embodiments, each stream of printed sheetscan be transported from the cutter to the collator with a sheettransport system comprised of at least one transport belt and at leastone backing roller opposing the transport belt. In embodiments,individual sheet transport, alternatively or additionally, can beaccomplished with a vacuum assist transfer machine as disclosed, forexample, in U.S. patent application 20030164587 (Gronbjerg).

The sheet delivery system preferably is adapted to simultaneouslytransport a plurality of the cut sheets in adjacent parallel sheetstreams. At the sheet stacker the individual sheet delivery system feedsthe respective sheet streams, containing the cut printed sheets, intobins to form respective stacks. The stacks can be collectively orindividually customized with respect to, for example: stack dimensionsand the number of stacks formed based, for example, on cutting criteria,and the number of printed sheets in each stack. Stack dimensions candepend on, for example, sheet thickness, sheet-count, stack-height,stack-weight, or like criteria. In embodiments, sheet-count is apreferred stack customization criterion, which is typically driven ordetermined, for example, by customer use requirements and ergonomichandling factors. Stack customization criteria can be readily translatedand programmed into the apparatus and production process of thedisclosure by appropriate manual or automated, adjustment ormodification, of the process equipment, controls, or both, such asreplacing the die-cutter plate to provide customized cut sheetdimensions, reprogramming the sheet counters or stack height sensors tocustomize the stack height, adjusting sheet alignment tolerance withineach stack, and like changes. When stack customization criteria andrelated quality criteria, such as print quality, are fulfilled inproduction, the resulting stack can be deemed to be “registered” andthose stacks are acceptable for further processing within the apparatus.“Unregistered” or out-of-register stacks can optionally be identified,marked, rejected, such as removed from the product stream, or likeremediation, at this or later points in the apparatus or productionprocess and analogously to the abovementioned removal of individuallyrejected cut sheets from the sheet stream transport.

In embodiments, the cut printed sheet transport system can be adapted,in conjunction with known or the abovementioned command and controlequipment, to reject cut printed sheets which do not have substantiallythe same cut-to-print registration, sheet dimensions, or bothattributes, as all other sheets in the job. The cut-to-printregistration, sheet dimensions, or both specifications, can preferablybe established manually or programmably during job set-up or can becalled-up from a computer or controller's memory. Rejected orout-of-spec cut printed sheets can be readily diverted and removed froma sheet stream at a point between the cutter and the collator, forexample, by a sheet grabber or a sheet diverter.

In embodiments of the present disclosure, the collator module for thecut sheet stream can alternatively be a rotary sorter as disclosed, forexample, in U.S. Pat. No. 4,582,421 (copying machine with rotary sorterand adhesive binding apparatus), appropriately modified to receivemultiple sheet streams into multiple stacks. In embodiments such arotary sorter can be further optionally adapted to receive and furthertransport the stacks to the conveyor module, with inversion oforientation or optional retention of stack orientation upon delivery tothe conveyor module.

Stack Conveyance

In embodiments, a conveyor module 17 can be adapted to receive, forexample in continuous batches, one or more registered stacks from thecollator module and to convey each registered stack, in batches, into astack stream. In embodiments, a conveyor module conveys (e.g., in theweb process-direction) on a first conveyor the registered stacks awayfrom the collator for a distance to further processing, such aspackaging. In embodiments, a conveyor module conveys (e.g., in the webprocess-direction) on a first conveyor the registered stacks away fromthe collator for a distance and thereafter the registered stacks can bedisplaced laterally or perpendicularly (i.e., with respect toweb-process direction), onto a second conveyor to form a merged stackstream. In embodiments, a stack stream as used herein can arise from,for example, a plurality of registered stacks being merged into a singlestream of stacks. In embodiments, a stack stream can also arise from,for example, bifurcating or splitting the abovementioned merged singlestream of stacks into two or more stack streams. In embodiments aplurality of stack streams can also arise from, for example, bifurcatingor splitting the registered stacks soon after being formed, into aplurality of stack streams.

In embodiments, a single conveyor, for example, oriented perpendicularto the sheet stream flow and the incipient batch stack formation, andsituated in close proximity to each batch stacker can be adapted todirectly receive the cut printed sheets and incipient stacks. Thus, theconveyor surface, when stationary, can serve as the base of the batchstacker where the sheet streams are compiled into stacks. Thereafter,the completed registered stacks are intermittently conveyed from thebatch stacker to subsequent packaging modules in a single stack stream.This single conveyor configuration eliminates the need for two conveyorsto get to the first packaging module, such as the first conveyor asillustrated and discussed for in FIG. 7 below, since a preferred stackstream merger into a single stream can be accomplished as the stacks areformed and there is no need to extend or “turn-the-corner” with ahand-off to a second conveyor.

Conveyor module 17 transports the stack stream or streams to and throughthe remainder of the apparatus and process modules. In embodiments, thestacks can be transported unsupported to subsequent stages of productionwithout damaging or disturbing the integrity of the unsupported stacks.“Unsupported” means that accessory support or supplemental structuralmaterials, such as sheets of cardboard, chipboard, stiffener sheets, orthe like, are not necessary to maintain side-to-side registration orshape, such as “squareness” or verticality of the stacks for square,rectangular, or irregularly shaped sheets. Various conventionalbelt-driven conveyor systems are known, available commercially, andsuitable for this purpose and as illustrated herein. Alternatively oradditionally, the conveyor module can have a belt or equivalent conveyormeans equipped with stack or bundle supports which are external to thebundle, for example, one or more tractor blades, fins, cleats, ribs,sidewalls, “one-way grass,” mole skin, and like rigid or resilientstructures or textures, or combinations thereof, and which supports canbe integral with (e.g., molded) or affixed to the conveyor, andoptionally can have a hinge. Conveyors having external supports arewidely commercially available.

Bundle Formation and Packaging

In embodiments, packaging each registered stack in the stack stream toform a bundle of printed sheets can include banding, overwrapping,optionally shrink-wrapping the applied overwrapper, stretch-banding, orcombinations thereof. If desired, the packaging can be accomplished bysimply banding the stacked printed sheets. A function of the band is tomaintain the integrity and order of the stack to, for example,facilitate subsequent packaging steps if any, improve ease and qualityof the dispensed printed sheets at the point of use, such as a labelapplication operation or facility. Surrounding a registered stack with aband can be accomplished in many ways, for example, wrapping an end of acontinuous band around the stack to size the band, cutting the sizedband, and fixing the ends of the band to form a continuous orsemi-continuous band, such as by gluing, welding, thermal fusing,dimpling, crimping, and like methods for forming a band or flexibleholder about at least a portion of the stack. Alternative bandingapproaches can include, for example, inserting the registered stack intoa pre-formed banding sleeve and optionally shrinking the sleeve,wrapping a pre-cut band around the stack and fixing the ends of theband, and like banding methods. Bands can be made of any suitablematerial, for example, rubber, plastic, paper, string, adhesive tape,non-adhesive tape, overwrap film, and like materials, or combinationsthereof.

If desired and for reasons disclosed herein, the packaging can beaccomplished by placing two or more bands around a registered stack. Thepackaging can also be accomplished by placing one or a single bandaround a registered stack.

In embodiments, the packaging can be accomplished by over-wrapping eachregistered stack, banded or un-banded, to form a wrapped stack or bundleof printed sheets. Over-wrapping of each registered stack can form asealed enclosure about the entire stack. Over-wrapping can provide animportant environmental barrier which protects the printed sheets from,for example, moisture, spills, humidity changes, dust, pollutants, andlike contaminants, which can damage or detract from the aesthetics orperformance properties of the printed sheets in downstream commerceapplications, such as labeling operations, label appearance, labelperformance, and consumer acceptance. Over-wrapping can be accomplishedwith any suitable wrapping material such as plastic, synthetic ornatural films, such as cellophane, acetate, polyvinyl acetate, and likematerials.

In embodiments, the method can further include, for example, placing theresulting bundled printed sheets in suitable container, such as a boxand sealing the box with tape. In embodiments, the method can furtherinclude placing a number of the sealed containers on a skid forconvenient handling and shipping, and optionally stretch-banding thecollected sealed containers into secure monolith for transport orstorage.

In embodiments, the method can further include, for example, furthercollating the bundled printed sheets into larger or secondary bundles(bundles of bundles), having for example from about 2 to about 20primary bundles, and which secondary bundles can also be optionallyoverwrapped, shrink-wrapped, stretch-banded (with e.g. polyethylene orlike materials), and like packaging, or combinations thereof to completethe packaging or optionally further containerized.

In embodiments, packaging can include, in the order recited, a firstbanding, a second over-wrapping, and an optional third shrink-wrapping.Alternatively, packaging can include, applying a band to each stack,placing one or more banded stacks in a container, and sealing thecontainer. Containers can be, for example, cartons, boxes, bags, cans,drums, supersacks, cargo-tainers, and like articles. The container canbe made from, for example, cardboard, wood, plastic, metal, or likematerials of construction. The container can include, if desired, asealable liner, such as a plastic bag or like membrane, which protectsthe bundled printed sheets packed in the container. Thus, the bandedstacks without an overwrapper but contained and sealed in the containerwith a sealable liner can resist changes in humidity and like potentialenvironmental or external effects.

In preferred embodiments, the conveyor module transports and feedsunsupported stacks through an optional bander module 18, which banderapplies at least one band around each stack to form a banded stack.Banding is often a requirement for proper and convenient handling ofstacks by an end-user of the printed sheets, such as a label applicatorconcern. Banded stacks may also be conveyed in the packing portion ofthe apparatus at higher speeds than without banding. Banding is not, ingeneral, a requirement of the process or apparatus of the disclosure,but is a preferred embodiment where higher productivity and economy aredesired. A commercial supplier of equipment for a bander module is, forexample, Sollas Holland BV of Wormer, The Netherlands. The Sollas modelAB50 banding machine is a preferred example.

The conveyor module next optionally conveys the stacks, banded orunbanded, through an overwrapping module 19, which wraps each registeredstack of printed sheets in an easy-to-peel overwrap film. Inembodiments, the overwrapper can be adapted to overwrap two or morebanded or unbanded stacks if desired. Suitable films include thosesupplied by RTG Films of Chalfont, Pa. A commercial supplier ofpreferred equipment for an overwrap module is, for example, SollasHolland BV. The Sollas model 20 wrapping machine is a preferred example.Other commercial suppliers of overwrap equipment includes Marten Edwardsand Petri, see Linfo Systems Ltd., mentioned below, which machines canbe adapted to overwrap from between 100 to 265 pieces (bundles) perminutes.

Overwrapping can prevent problems associated with handling ormanipulating exposed printed sheets in subsequent processing.Overwrapping can also protect the bundled printed sheet product frommoisture and humidity, especially after it leaves the labelmanufacturer. Although preferably produced in a stable environment, thebundled printed sheets, such as for label application, may be shippedinto substantially different climates, for example, a dry canningfactory in New Mexico where ambient humidity at the application site mayless than about 10-30%, or a water bottling plant in Oregon whereambient humidity at the application site may exceed 60%. The overwrappreferably is not removed from the wrapped bundle until just prior toapplication, so that exposure of the labels to the ambient environmentis minimized to, for example, as little as 15 minutes or less.

The conveyor module can next deliver the resulting stacks, overwrappedor unwrapped, to an optional containerizer module 20 where, for example,a robot or an operator places the stacks or bundles of printed sheetproduct, banded or unbanded, overwrapped or unwrapped, in a suitablecontainer, such as cardboard boxes or like suitable containers. Anoptional seal module 21 can be used to, for example, apply a tape sealto the containers containing the bundled printed sheets. The sealedboxes can then be optionally placed, manually or robotically onto, forexample, pallets or skids at an optional carrier module 22 for staging,shipping, or delivery to a customer or warehouse. Commercially availableequipment from manufacturers of various conveyer systems, parcelhandling systems, or robotic systems can be readily adapted for theboxing, sealing, skidding, or like packing operations. For examples ofcommercial suppliers and details of fully automatic and customizablesheet feeders, overwrap equipment, shrink-wrap equipment, shrinktunnels, bag sealers, and like secure packaging equipment, see LinfoSystems Limited, of Toronto, Ontario, Canada, (www.linfo.ca).

In embodiments, advantages of the apparatus and process of makingbundled printed sheets of the disclosure includes overall acceleratedproduction speed and increased volume throughput compared to knownproduction processes for bundled printed sheets. The total time requiredbetween, for example, printed sheet formation (at 11 to 14) andapplication of packaging materials (at 18 to 22) is greatly decreased toless than about 1 to 4 minutes. For example, in current high volumeprinted label production systems, considerable time passes, such as fromabout 6 to about 48 hours or more, from the time the labels are printedand until the time the labels are packaged, such as boxed, because ofthe need for inks or coatings to properly dry or cure. Such time lapsescan increase the likelihood that moisture will evaporate from, orpenetrate into a printed sheet and potentially cause print quality orhandling issues for individual sheets in use.

FIG. 2 illustrates in embodiments, an alternative sheet-fed basedapparatus for making the bundled printed sheet articles of the presentdisclosure. The apparatus or production system of FIG. 2, is anautomated sheet-fed based system for high volume production ofindividual printed sheets cut from the fed-sheets in accordance with thepresent disclosure. Sheet feeding module 210 can be, for example, asheet-feeder capable of loading pre-cut sheets and which pre-cut sheetsare further cut to size. Sheet-feeder devices are known and commerciallyavailable and can be readily adapted for use in the apparatus andprocess of the present disclosure.

The feed-sheets can be either unprinted or pre-printed. In eitherinstance, the feed-sheets can be further processed including, forexample, charging, printing, coating, treating, drying, chilling, andlike processes, or combinations thereof, analogously to the web-basedsystem of FIG. 1 described above, such as embodied by the aforementionedapparatus and processing associated with modules or components of 12 to22, 23, 25, and 26. Thus, for example, prior to cutter module 240 therecan be incorporated an optional print module (not shown) having a printengine suitable for printing on the fed-sheets, simplex or duplex, orlike printing equipment. Similarly and optionally available forincorporation into the system of FIG. 2, but not shown, are modules orstations corresponding to those shown or mentioned for optional modules13(a-e) in FIG. 1. Other modules schematically shown in FIG. 2, includea matrix removal module 250, a discharging device 255, such asantistatic bar or static eliminator which can be use toelectrostatically condition or treat the web before or after the printmodule, collating module 260, conveyor module 270, banding module 280,overwrapping module 290, containerizing module 291, labeling module 292,optional sealing module 293, and carrier module 294. It will be readilyunderstood that conveyor modules 17 and 270 in FIGS. 1 and 2 and asdescribed herein, are not limited to a single linear conveyor asschematically illustrated in FIGS. 1 and 2. A sheet-fed or discontinuousprinting and finishing system employing, for example, a xerographicimager and a vertical collating bin array for sheet stacking or sorting,is disclosed for example, in U.S. Pat. Nos. 4,444,491, and 4,368,972.Commercial suppliers of automatic and customizable sheet feeders, andlike paper handling equipment or accessories include, for example, XeroxCorp., Hewlett-Packard Corp., and Canon, Inc.

The present disclosure, in embodiments, is directed to an apparatus andmethod for preparing substantially identical bundled printed sheetswhere, for example, the dimensions of each sheet are substantially thesame as every other sheet in the bundle and where the dimensions of eachbundle are substantially the same as every other bundle. Thus, thepresent disclosure in embodiments is distinguished from known documentprinting, reproduction, or reprographic systems having, for example,printing, collating, finishing, and like capabilities, but where, forexample, the resulting printed sheets are not precisely cut into a twoor more smaller identical printed sheets from fed-sheets or a continuousweb. However, in embodiments, the present disclosure can include aspectsof known web-based or sheet-fed document printing, reproduction, orreprographic systems without departing from inventive aspects of thepresent disclosure. Thus, in embodiments of the present disclosure, thebundled printed sheets can have for example, sheet-to-sheet print orimage content which is constant, variable, or both. Additionally,embodiments of the present disclosure can provide substantiallyidentically dimensioned printed sheets and substantially identicallydimensioned bundled printed sheets which can be fashioned into, forexample, multi-page documents, such as bound booklets, manuals,brochures, coupons booklets, check bundles, or like printed publicationsor collateral materials, see for example, U.S. Pat. No.4,368,972, orused to modify multiple page documents, such as with correction labels,advertising labels, bookmarks, promotional inserts, and likeapplications.

FIG. 3 illustrates in embodiments, a block diagram overview of aweb-based process for preparing bundle printed sheets of the presentdisclosure, with for example the apparatus illustrated and described inFIG. 1. For example, printing 310 can be on, for example, a liner-lessprintable web, followed by optional application of a web coating 320,for example an adhesive or other suitable coating material 322 to oneside (e.g., back-side) of the web, and a varnish or antistatic coatingmaterial 324 to the other side (e.g., front-side) of the web. Theprinted and optionally coated web can be preferably die-cut 330 into oneor more printed sheet streams with any accompanying waste matrix beingdiscarded 335. The printed sheet streams are collated 340 intoregistered stacks, the stacks are conveyed 350 into one or more stackstreams, and each stack is packaged 360 with one or more packingmaterials or steps into a bundle of printed sheets. The packaged bundleof printed sheets can optionally be further containerized 370 orpackaged, for example, with a banding machine, an overwrapping machine,a heat-shrink machine, a containerizer machine (e.g., a box maker or boxloader), a stretch banding machine, a palletizer, and like operationsand devices, or combinations thereof.

FIG. 4A illustrates in embodiments, a perspective of a portion of aweb-based apparatus for preparing bundle printed sheets including, forexample, a web-based substrate feeding 405, a printing module 410 whichcan include, for example, one or more or a plurality of print engines orprint towers having the same or different print technology (e.g., offsetand inkjet), one or more coating or treatment stations such as UV lightcure of printed inks or coatings, or combinations thereof, a drummounted die-cutting module 430, waste matrix generation and removal 435,resulting individual cut printed sheets 432 the linear flow of whichcomprises a printed sheet stream 440. Collation (not shown) of a portionof the printed sheet stream provides a registered stack 442. “W”represents the width dimension of the web, “w′” represents the widthdimension of one or more cut printed sheet, “l′” represents the lengthdimension of the cut printed sheets, and “h” represents the heightdimension of a registered stack. It is readily apparent that W isgreater than w′ even when only a single w′ sheet is cut from across theweb using a die-cutter which also generates a waste matrix. It is alsoreadily apparent that w′ can be greater than, less than or equal to l′.

FIG. 4B illustrates in embodiments, a section view of a cutter module ina web-based apparatus for preparing bundle printed sheets of the presentdisclosure including a web substrate feed 410, a rotary die-cutterincluding a drum 430 having readily interchangeable die-cutting elements431, juxtaposed die anvil 433, optional juxtaposed nip roller 450, niproller pair 455, and optional non-contact separator device 460. Inoperation the cutter module configuration of FIG. 4B provides enhancedperformance and process reliability having, for example, reduced jams,complete separation of cut sheets 432 from the waste matrix 435, reducedcut sheet “fly-away,” and like enhancements. Juxtaposed nip roller 450ensures reliable substrate feed to the cutter. Nip roller pair 455,having for example cutter synchronized and regulated speed, provides acontrolled constant tension and pull force to facilitate removal of thewaste matrix from the separation area and delivery to a matrix take-off(not shown). Separator device 460 can be, for example, a static charger,a static eliminator, an air knife, a fan, and like devices, orcombinations thereof. A preferred combination for use in the separatordevice 460 is a static charger and an air jet, which combinationdisperses electrostatic charge to the separation region between the cutsheet and the matrix. Although not desired to be limited by theory, thecombined action of the mechanical forces of the air jet, nip roller pair455, and the electrostatic repulsion of like-charged surfaces or chargeneutralized surfaces of the waste matrix and the incipient cut sheetappear to facilitate smooth and reliable separation between the cutsheets and the waste matrix. In embodiments, the cutter module of FIG.4B can optionally include a bottom-side vacuum transport belt 475 totransport or assist in the transport of cut printed sheets to downstream processing, such as stacking. The cutter module of FIG. 4B canalso optionally include a debris disturber 465, such as an air knife orlike non-contact device to assist in the removal of debris from the cutprinted sheet products prior to stacking. The cutter module of FIG. 4Bcan also optionally include an abrader or sander article 470, such as ametal plate or sheet coated with a high durability abrasive materialaffixed to the surface of the article, for example, carbide particles,carborundum particles, diamond grit, sand, and like abrasive materials,or combinations thereof, to further assist in the removal of debris fromthe cut printed sheet products, and optionally buffing the printedsheet, prior to stacking. In embodiments, the cutter module of FIG. 4Bcan include one or more debris disturber 465, such as an air knife, oneor more abrader or sander article 470, and one or more debris removaldevice, such as a vacuum collector manifold 480. In a preferredembodiment, the cutter module of FIG. 4B can include a debris disturber465, such as an air knife, an abrader or sander article 470 for eachsheet stream, and at least one debris removal device, such as a vacuumcollector manifold 480. In embodiments, the cutter module of FIG. 4B canoptionally include the abovementioned components for accomplishingbursting, such as an edger or slitter (not shown) and debris removaldevice such as a vacuum collector manifold 480. The foregoing web-basedembodiment of FIG. 4B can adapted for use in a sheet-fed based apparatusand process embodiments of the present disclosure.

FIG. 5 illustrates, in embodiments, a block diagram overview of asheet-fed based process for preparing the bundle printed sheets of thepresent disclosure, with for example the apparatus illustrated anddescribed in FIG. 2. For example, feeding cut-sheets 505, followed byprinting 510 can be on, for example, a plain or bond cut sheet paperstock, followed by optional coating 520 on either or both sides of theprinted cut sheets, for example, an adhesive, varnish, antistat, or likecoating materials. The printed and optionally coated sheets can bedie-cut 530 into one or more printed sheet streams. The printed sheetstreams are collated 540 into registered stacks, the stacks are conveyed550 into one or more stack streams, and each stack is packaged 560 intoa bundle of printed sheets. The packaged bundle of printed sheets 560can optionally be further containerized 570 or packaged, for example,with a banding machine, an overwrapping machine, a heat-shrink machine,a containerizer machine (e.g., a box maker or box loader), a stretchbanding machine, a palletizer, and like operations and devices, orcombinations thereof.

FIG. 6A illustrates in embodiments, a perspective view of a portion of acollator module 16 in communication with a portion of a conveyor module17 of an apparatus for preparing bundled printed sheets. Sheet streamtransport 610, such as belts, rollers, vacuum transport belts, and likedevices, or combinations thereof, transport and deliver the cut sheetstreams to a batch stackers 620, preferably an optional second batchstacker 625, or optional additional batch stackers (not shown), to form,for example, a plurality of neatly stacked and registered sheets inadjacent stacks 630. Side walls 623, tab-stops 650, and like structures,can be included in the stacker to form a bin or chute for receiving thesheets and forming stacks. An optional elevator 660 can be employedwhen, for example, more than one batch stacker is stacking to shuttlecompleted batches of stacks 680 (e.g., 5 stacks across in each batch ofstacks shown) from their respective stacker unit to a batch stackconveyor 670. The sheets received by the stacker can optionally beregistered to achieve a unitary shape or uniform stack dimensions by,for example, jogging. Jogging can be accomplished by, for example,vibrating the side walls 623, tab-stops 650, and like structures, orcombinations thereof, while the sheets are being collated into stacks inthe stacker.

FIG. 6B illustrates in embodiments a related alternative to the conveyormodule shown in FIG. 6A. Here the collator module (16 in FIG. 6A), againcollating individual sheets into stacks within bins or chutes withsidewalls 623, is in communication with a reconfigured conveyor 675situated next to the optional elevator 660 (hidden). This conveyorconfiguration is adapted to directly receive the stack batches from theelevator conveyor. Conveyor 675 is equipped with multiple rollers 685(six shown) which facilitate a smooth transfer or “hand-off” of thebatch stacks from the elevator conveyor in the multi-stack streamprocess direction to perpendicularly (in a horizontal plane) situatedconveyor 675. It will be readily evident that conveyor 675 can beoperated uni- or bi-directionally and as described for conveyor 690 inFIG. 7 a below. Once the stacks reach a proper position on conveyor 675,a system controller, like controls, or an operator can cause a pluralityof conveyor belts 677 to raise-up and above the level of the rollers 685and cause the belts 677 to convey the stacks in a single stack stream tofurther down stream processing. Additional details of the conveyorconfiguration of FIG. 6B are shown in FIG. 7B and discussed below.

Collating the cut printed sheets can be accomplished, for example, witha collator having a receiver for receiving and registering each streamof printed sheets into an incipient registered stack. The receiver canbe any suitable member for receiving the printed sheets, such as a bin,a tray, a pocket, a chute, and like members or structures. An example ofa suitable receiver member or structure is associated with acommercially available Gannicott machine, for example, modified tosimultaneously receive multiple cut printed sheets into separated binsor trays. Each bin or tray can have, in embodiments, two side-walls, afront wall, and an optional back wall. The tray or bindexer can have, inembodiments, sidewall fingers which permit mechanical “jogging” of theprinted sheets as they are received from the die-cutter or other cuttingdevice by the collator's respective stacker bins. Collating of a numberof streams of printed sheets preferably produces a correspondingly equalnumber of registered stacks. In embodiments, registered stacks or theirresulting bundle of printed sheets can have, for example, from about 10to about 10,000 printed sheets, preferably from about 10 to about 5,000printed sheets, and more preferably from about 10 to about 1,500 printedsheets, where the preference here reflects, in embodiments, a balancebetween minimized packaging (larger stacks and economies of scale) andadequate stack or bundle size for convenient manual handling (smallerstacks and human factors) in a particular industrial application, suchas label applicators. Other bundled printed sheet sheet-counts maypreferred in other applications.

In embodiments, the registered stacks can be, for example: vertical andunsupported, (i.e. sheets laying flat with one face oriented downwardand the other face oriented upward, wherein the sheets are stackedupward atop one another); vertical and supported; or horizontal andsupported. Stack “support” in this regard refers to, for example, anysuitable support structure or a mechanism suitable for maintaining thestack in a localized position while it is being formed, and to maintainthe stack's desired properties, such as shape, handling, and appearance,during and after the time the stack is formed. A support structure or amechanism can be, for example, a portion of the collator, such as a wallor stop. “Jogging” the stack with respect to a mechanical collator andcollating the printed sheets refers to mild agitation or a shufflingdisturbance which causes the cut sheets to align into more uniform orunitary stacks. “Jogging” of the stack with respect to an operatorrefers to mild manual agitation or shuffling disturbance, such astapping the stack or bundle with a wood block, which also causes the cutsheets to align into more uniform or unitary stacks or bundles. Inembodiments the stacks can be supported for a time, for example, whilebeing formed, that is, during the stacking of sheets, and unsupportedfor a time, for example, while being transported on a conveyor.

The registered stacks can be, for example, edge-to-edge registered,side-to-side registered, height-registered, edge-registered,width-registered, weight registered, or combinations thereof. Inembodiments, the stack height is predetermined, for example, by customerpreferences, limits on the change range in the collator tooling,optimizing space utilization in, for example, containerizing or likepackaging or storing considerations. In embodiments, achieving thepredetermined stack height can be accomplished by, for example, a sheetcounter, or similar mechanism associated with the collator. A Gannicottdie-cutting machine having a stack height counter is commerciallyavailable. Preferably, each registered stack is at least heightregistered and edge-to-edge registered. More preferably each registeredstack is at least edge-to-edge registered.

FIG. 7A illustrates, in embodiments, a perspective view of a portion ofa conveyor module 17 of an apparatus for preparing bundled printedsheets of FIG. 6A including the above mentioned first batch stackconveyor 670 for conveying completed batches of stacks 680 to a secondbatch stack conveyor 690. As shown, a stack stream comprised ofsuccessively produced batches of stacks 680, for example, having fivestacks each, is conveyed on conveyor 670 and transferred to conveyor 690to form a merged single stack stream 710. Optionally, conveyor 690 canbe adapted to operate bi-directionally or reciprocate to permit themerged stack stream to provide a second stack stream 720 when theconveyor 690 is operated in the reverse direction 720. The merged stackstreams 710 or 720 convey the stacks in “single-file” fashion onconveyor 690 to subsequent packaging stations. Conveyors 670 and 690 canbe a single belt, a plurality of belts, rollers, and like conveyordevices, or combinations thereof.

FIG. 7B illustrates in embodiments, a view of a portion of the conveyormodule shown in FIG. 6B and discussed above. A first conveyor 660, forexample in embodiments, the elevator conveyor of FIG. 6B transfers batchstacks to a second conveyor 760. Optional support 750 having an optionalroller can be included to further facilitated the transfer and avoid orminimize, for example, stack tipping or disruption of sheets within theuniform stacks. Second conveyor 760 can include plural rollers 765 forreceiving and positioning the batch stacks on conveyor 760. In oneexample, plural belts 770 on conveyor 760 were situated perpendicular toplural belts of first conveyor 660. Stack batches advanced on conveyor660 were transferred to conveyor 760 on rollers 765 and thereafterplural belts 770 were engaged to convey a single stack stream to furtherprocessing 780

In embodiments, a first conveyor conveys one or more stacks, such asfrom about 1 to about 80 stacks, more preferably 2 to about 40 stacks,and even more preferably about 5 to about 20 stacks, at the same timefrom the stacker to a second conveyor. Here the preference reflects adesire to optimize or match sheet handling and stack handling hardwareand capacity with total throughput economics. The second conveyor's pathor process direction can be situated perpendicular to the firstconveyor. In embodiments, to provide greater stack handling and stackthrough-put, the first conveyor can include an elevator which permitsswitching stack staging and conveyance between an upper first conveyorand a lower first conveyor. For example, while the upper first conveyorconveys stacks to the second conveyor the lower first conveyor is heldstationary to receive stacks. When the upper first conveyor hascompleted conveyance of its stacks to the second conveyor and the lowerfirst conveyor has received its stacks the elevator changes thepositions and the roles of the upper and lower first conveyors to stackstaging and stack conveyor, respectively. Thus, in embodiments, thecollator forms one or more stacks by continuously collating printedsheets. The completed stacks are placed onto one or more conveyors andconveyed to a second conveyor situated, for example, perpendicular tothe first conveyor. The perpendicular orientation of the second conveyorrelative to the first conveyor causes the stacks conveyed by the secondconveyor to be conveyed in the same direction and in a single stream,that is “single-file.” In embodiments the second conveyor can conveyalternating stack batches or loads received from the first conveyor indifferent directions, such as the opposite (180 degrees) direction,perpendicular (90 degrees) direction, and like acute or obtuseintermediate angle directions, to provide two stack streams(“split-stream”) where each stack stream is separately packaged in oneor more packaging operations. In embodiments, where for example, thecollator module has two batch stackers operating in and situated in anover-under relation, the conveyor module can include, for example, aconveying elevator, the elevator being operable to alternately receive abatch of stacks from each batch stackers, and to convey the receivedbatch of stacks to a first conveyor for further processing. The firstconveyor can convey the received batch of stacks as a stack streamuni-directionally to the packaging module. The first conveyor can alsobe configured to split the merges single stack stream into two or morestack streams, and to convey the received batch of stacks as a stackstream bi-directionally to two or more packaging modules.

In embodiments, where for example, the collator module has two batchstackers operating in an over-under relation, the conveyor module caninclude, for example, two conveyors, with each batch stackers having oneof the two conveyors dedicated to receiving its batched stacks, and eachconveyor being adapted to convey the batched stacks to further packagingas batches of stacks (e.g., five stacks abreast) or as a single stackstream (i.e., one stack abreast or single-file). Thus in embodiments ofthe disclosure, there are number of conveyor configurations, which canaccomplish efficient conveyance of batch stacks or stack streams andwithout an elevator shuttling between batch stackers or otherwise.

FIG. 8A-8D illustrates, in embodiments, examples of various cut patternsfor forming cut printed sheets.

FIG. 8A illustrates an example of an “aligned-cut” pattern where a web810 traveling in process direction 812 is cut with a cutter module, suchas a die-cutter, to produce a cut sheet 815 which sheet is separatedfrom the web to form a sheet stream and its corresponding cut-out voidwhich is part of the waste matrix. Imaginary reference lines 820 showthe relative “aligned” orientation of the cut sheet 815 to the normal(perpendicular in-plane) direction across or traversing the web processdirection.

FIG. 8B illustrates an example of a “staggered-cut” pattern where a web810 traveling in process direction 812 is cut with a cutter module, suchas a die-cutter, to produce a cut sheet 815 which sheet is separatedfrom the web to form a sheet stream and its corresponding cut-out voidwhich is part of the waste matrix. Reference lines 820 show the relative“stagger” orientation of cut sheet 815 to adjacent stagger cut sheets830 to the normal direction across the web process direction.

FIG. 8C illustrates an example of a “skewed” angle-cut pattern where aweb 810 traveling in process direction 812 is cut with a cutter module,such as a die-cutter, to produce a skewed-cut sheet 840 having a veryslight parallelogram shape which sheet is separated from the web to forma sheet stream and its corresponding cut-out void which is part of thewaste matrix. Reference regions 845 show the relative “skew” orangle-cut orientation of the cut lines in the process direction of cutsheet 840.

FIG. 8D illustrates an example of a “square” angle-cut pattern where aweb 810 traveling in process direction 812 is cut with a cutter module,such as a die-cutter, to produce a square-cut sheet 850, that is havingall square corners 855, and which sheet is separated from the web toform a sheet stream and its corresponding cut-out void which is part ofthe waste matrix. Reference regions 860 and 865 show the slight shift orskew angles of the cut lines in the process direction and the across theprocess direction, respectively.

It is understood that the abovementioned cut patterns and methods forweb cutting can be readily adapted to and are applicable to sheet-fedcutting embodiments. It is also understood that the abovementioned cutpatterns are illustrative and are not intended to restrict the possibleshapes or dimensions of the cut sheets, stacks, or bundles of thedisclosure.

FIG. 9A illustrates, in embodiments, an exemplary bundle of printedsheets 900 of the present disclosure, having a plurality of registered,neatly stacked, cut sheets 910, having printing (e.g., images, patterns,line art, and like marks), printed indicia (e.g., text, figures, andlike marks), or both 920, on one or both sides, such as label or productinformation, a band 930 encompassing the stack of printed sheets of thebundle, and a band overlap region 935 which can provide a point ofattachment or fastening of the band to itself.

FIG. 9B illustrates, in embodiments, the banded bundle of printed sheets900 of FIG. 9A further including a clear or translucent protectiveoverwrapper 950, and one or more optional tear-tapes or pull-tabs 960 tofacilitate unwrapping of the overwrapped bundle. In embodiments, theoverwrapper 950 can be shrunk by, for example, known shrink-wrappingmethods, such as the application of heat or radiation, to form a tightlysealed bundle.

FIG. 9C and 9D illustrate, in embodiments, other examples of bundle ofprinted sheets 900 of the present disclosure having alternative stack orbundle geometries while still having a plurality of registered, neatlystacked, cut sheets 915, images, printed indicia, or both 920, on one orboth sides, such as label or product information, a band 930encompassing the stack of printed sheets to form a bundle, and anoptional band overlap region 935 which can provide a point of attachmentor fastening of the band to itself. FIG. 9C and 9D additionallyillustrate that, in embodiments, the sheets and their resulting stackand bundles of printed sheets can have a unitary shape other than a cubeor a parallelepiped, including for example irregular aspects, curvedaspects, notched aspects, peaked aspects, and like aspects, orcombinations thereof, which aspects taken together can be functional,aesthetic, or both. The bundle of printed sheets of FIG. 9C can be forexample a food product label or a promotional item. FIG. 9D can be forexample a sports product label or insignia label.

In embodiments, other advantages of the in-line apparatus and productionprocess for making bundled printed sheets of the present disclosure caninclude, for example, particularly when a precision rotary die-cutter isused: chipboard or like rigid stack supports are not required tomaintain stack integrity during or after manufacture; the apparatus andproduction are less costly to operate compared to alternative systems;and the apparatus and production process, in embodiments, provideimproved product-to-product consistency, such as sheet-to-sheet andbundle-to-bundle size uniformity, lot-to-lot uniformity, that is wherethere is time gap between identical print jobs, print registration, andprint registration to cut edges of the sheets and their bundles. Bycomparison current state of the art guillotine cutting systems providecut sheet variance of greater than about ±{fraction (3/64)} inches. Theimproved print registration to cut edges reduces paper waste, ink waste,reject waste, and improves the appearance and customer acceptance of thebundled printed sheets and the individual printed sheets, such as inconsumer product label applications. Furthermore, the apparatus andprocess of the disclosure can reduce the total time to manufacture asupply of printed sheets, such as labels, from 12 to 24 hours to, forexample, about 1 to 4 minutes. Standing or storing of cut printed sheetsor bundles of printed sheets, for drying, curing, or like processes, isnot necessary in embodiments of the disclosure. The bundles of printedsheets and the cut printed sheets therein, in embodiments of thedisclosure, can be ready, if desired, for immediate customer use, forexample, in the application of labels to articles. In embodiments thehigh cut-to-print registration can provide printing processes andproducts with design or artwork freedom advantages, for example, havingartwork capabilities with uncommon bleeds, and avoiding the requirementfor solid “banded” borders which are typically required, for example, inconventionally prepared guillotine cut-labels.

Table 1 provides an exemplary operation-time summary of a web-basedproduction system for the manufacture, start-to-finish, of a singlebundle of printed sheets product of the disclosure. In embodiments ofthe disclosure, in the manufacture of bundled printed sheets there canbe incidental or intentional “holdup,” that is a slight delay or aslow-step in one or more manufacturing steps, for example, toaccommodate limitations on equipment or operators, such as in manualpackaging operations, shift changes, and like circumstances. Holdup canbe minimized or eliminated, as desired, with different configurations,equipment, belt speeds, and like modifications, or combinations thereof.TABLE 1 Approximate operation-time summary for web-based manufacture ofa single bundle of printed sheets. OPERATION/MODULE TIME web printing (8color offset with 1-30 seconds concurrent intermediate UV cure; webspeed average = 300 feet per min.) web coating (varnish - single side)<1 second  web drying (air) <5 seconds web chilling (chilled rollers) 1-5 seconds cutting (die-cutter) <1 second sheet transfer (sheetstream)  1-2 seconds collating (for stacks of 1,000 sheets 30seconds-120 seconds each with 2 batch stackers) conveying (one stack tobanding; 1^(st) and  5-30 seconds 2^(nd) conveyors) packaging 100-160seconds (banding - 2 bands applied  (5-10 seconds) simultaneously)(complete plastic overwrap) (90-120 seconds) (containerizing -corrugated box (<5 seconds) wrap) (box sealing - tape)  (1-10 seconds)(carrier loading - each box  (5-15 seconds) stacked by an operator)TOTAL about 140 to about 350 seconds (about 2.5 to about 6 minutes)

The bundled printed sheet products of the present disclosure provide asuperior product for print-to-cut quality and stack uniformityproperties, produced in less time, and a lower relative cost, comparedto other available apparatus and methods. The bundled printed sheetproducts of the present disclosure, with or without additionalpackaging, are suitable for immediate use by a customer or user, forexample, a packaging or labeling vendor-customer engaged in a high speedlabel application operations. Such a product is more responsive tocurrent and future customer needs, for example, for print-on-demandavailability or just-in-time inventory, and their concomitantadvantages. The bundled printed sheet products of the present disclosurecan provide a vendor-customer with bundled sheet products, in highquality and in high volumes, which products have less overall waste, forexample, less waste packaging and less waste or unusable printed sheetswhich sheets historically had to be detected and discarded, andtypically caused costly disruption or unnecessary down-time in customeroperations.

The bundle printed sheets of the present disclosure, such as a bandedand overwrapped bundle of labels, provide benefits to the process ofapplying or attaching a printed sheet to an article, such as a consumerproduct container or package. With previous label manufacturing methods,the printed labels often needed to be supported with chipboard, or othersimilar cumbersome materials, and shrink-wrapped to unify the stack. Touse those bundled labels in a labeling machine, the shrink-wrap is cutoff, the chipboard support is removed, and the label stack is placed ina label applicator machine to be fed onto the receiver package. Thismethod of placing labels in a label applicator machine is prone toproduce misaligned labels, which can in turn cause label misfeeds orjams, and can result in inferior label application, waste or rework, andcompromised label application productivity. The present disclosureprovides solutions to these problems. In embodiment, the combination ofbanding and overwrapping the stacks simplifies placing printed sheetlabels in a label applicator machine. The equipment operator or robotcan simply unwrap the stack with a highly visible tear-strip ortear-tape similar to that used on clear cigarette packaging. While thestack is still supported by the band, the label bundle can optionally befanned-out and then loaded in the label applicator machine. Then, usingfor example a band cutter, the band can be slit and removed, leaving theresulting label stack in ideal position and alignment for feedingthrough the label machine.

The printed sheets of the present disclosure can each have highuniformity, such as the abovementioned low variance in cut-to-printregistration, and the low variance of the length and width dimensions.Consequently, when the substantially identical sheets are stacked, suchas prior to or subsequent to bundling by banding, overwrapping, or both,highly uniform stacks and ultimately uniform bundles of printed sheetsresult. Highly uniform stacks or bundles of printed sheets of thepresent disclosure are enabled by, for example, the method of making andthe apparatus for making as disclosed herein. The high print-to-cutuniformity and the high dimensional uniformity of the printed sheets canbe attributed to precision printing methods and precision cuttingmethods of the present disclosure. The high uniformity of a stack, thatis a group or ream of stacked sheets, flows the combination of theaccurately dimensioned sheets (i.e., low sheet-to-sheet dimensionalvariation) and the apparatus and methods used for stacking the sheetsand the apparatus and methods used to package the sheets into bundles.The abovementioned high uniformity of a stack enables one to readilyobtain a high uniformity bundle of printed sheets, for example, afterthe uniform stacks are packaged, such as when the stacks are banded,overwrapped, boxed, or combinations thereof. The apparatus and methodsof the present disclosure used to make and package the sheets and theirresultant bundles, also provide an apparatus and method for making largenumbers of bundled printed sheets with high bundle-to-bundle uniformity.Thus, as an example of high bundle-to-bundle uniformity, the firstbundles manufactured in a print job, such as bundles 1 to 10, aresubstantially identical in all aspects to bundles manufactured in themiddle, such as bundles 18,490 to 18,500, or the end, such as bundles36,990 to 37,000, of a continuous 24 hour print job.

In embodiments of the present disclosure, the apparatus and methods canenable the manufacture of on-average, for example, from about 1 to about150 stacks or bundles of printed sheets per minute. It will be evidentthat the actual number bundles made or production rate can depend uponmany different variables, for example, web speed, web width, printedpiece cut dimensions, number pieces cut per web width, conveyor numberand speed, banding and wrapping efficiencies, and like considerations.The production rate in this or similar linear productions systems of thepresent disclosure is typically rate limited by the slowest step oroperation. The present disclosure can be adapted to escape from theabove mentioned limitations of a linear or assembly line, for example,by “splitting” or dividing the stack streams to permit parallel orconcurrent processing and increased through put productivity. Inembodiments, the bundles can contain any arbitrary number of printedsheets. It will be evident to one of ordinary skill in the art that, forexample, economic, operational, handling, customer requirements, andlike considerations, that the bundles preferably have, although notrequired, approximately the same number of sheets in each bundleprepared during the same job. In embodiments each stack or bundle ofprinted sheets can contain, for example, from about 10 to about 10,000printed sheets, preferably from about 10 to about 5,000 printed sheets,and more preferably from about 50 to about 1,500 printed sheets. Othersheets-per-bundle counts can be readily prepared if desired. It will bereadily appreciated the number of bundles of printed sheets produced perminute can be multiplied by a factor which corresponds to operatingadditional production lines under approximately the same conditions andparameters.

It will be readily appreciated and understood from the presentdisclosure that the dimensions of a stack and the resulting packagedbundle can depend upon, for example, the thickness (height orz-dimension) of the web stock or sheet-fed stock selected, the thicknessadded to the web stock or sheet-fed stock as a result of, for example,printing, coating, conditioning, or like additions or treatments, thearea size (x-y dimensions) of printed sheets cut from the web stock orsheet-fed stock, and the contribution of the packaging materials to theoverall bundle dimensions. In embodiments of the present disclosure, thesize of the bundle of printed sheets can be any suitable dimensions, forexample, to provide bundles that are particularly useful to a user,consumer, or processor of bundled printed sheets, such as a person ormachine, such as a robot, which handles the bundles or the constituentindividual printed sheets within a bundle, such as, a label applicatormachine and its operator. In the example of a label applicator machineand it's operator, bundles preferably have dimensions which makehandling of the bundles by the operator convenient, such as readily heldin a typical human hand, and unwrapped, unbanded, or both, with theother hand. Thus, in embodiments, a finished bundle of printed sheetscan be, for example, about 1 to about 2 inches wide, about 2 to about 4inches high, and about 3 to about 10 inches long. The foregoingdimensions being preferred, in embodiments, by operators or handlers andin view of human factor considerations. Other bundle dimensions can bereadily selected and achieved in embodiments of the disclosure.

The high dimensional uniformity of each sheet in the bundle, the highdimensional uniformity of each bundle itself, and the highbundle-to-bundle dimensional uniformity provides, for example, bundlesand printed sheets which are readily loaded and dispensed from a labelapplicator machine and with high reliability, for example, with minimalor free-from stack or label jamming or stack or label rejection from thelabel machine.

The bundled printed sheet product or the printed sheets within thebundles of the present disclosure can have a number of desirable aspectsor advantages depending upon the details of their manufacture and thedetails of their use or application as mentioned below. In one aspect,the printed sheets can have superior gloss properties, for example, whenthe printed web or sheets during manufacture are coated with a glosslayer or varnish overcoat. Generally, the gloss coated or varnish coatedprinted sheets can have, for example, a reduced glue use or reduced gluerequirement by a label applicator machine in applying the printedsheets, such as a label, to an article, such as a bottle, can, and thelike, where for example, the ends of the coated printed sheet areoverlapped and attached to each other with an adhesive. Alternatively,an adhesive can be applied to all or a portion of one side of theprinted sheet to contact and affix the printed sheet to an article.

Accordingly, the bundles, the printed sheets within bundles, or theprinted sheets when used, have lower rejection rates and higheracceptance rates among users, such as downstream manufacturers,customers, or consumers, compared to printed sheets made by knownprocesses. In still yet another aspect, the printed sheets within thebundles and the bundles can be used without or with minimal “fanning” bya user or operator prior to use. “Fanning” refers to the practice of,for example, quickly parsing the sheets in the stack, for example, toseparate or aerate adjacent sheets in a stack.

In embodiments, the printed sheets in the bundles can be usedimmediately or very soon after their manufacture, for example, withinseconds or minutes, especially if the web or fed-sheets are printed andcured with ultra-violet (UV) curable ink(s) or with a UV curableovercoating, such as an ultraviolet curable varnish formulation, andthereafter cured with a suitable UV source to provide printed or coatedprinted sheets. UV curable over-coatings, in-line or web coatingdevices, and UV light sources for curing are commercially available.Thus, printed sheets and their subsequently formed bundles can be madeand used on-demand and do not required extended or lengthy time delaysassociated with an intermediate drying step and which drying step mayadditionally require special environmental conditions, such astemperature or humidity control, or handling precaution, intermediatestorage or warehousing, and like considerations. Uncoated printed sheetsor sheets coated with water or aqueous based UV varnishes or coatingstypically tend to be more porous compared to organic based UV varnishesor coatings and tend therefore more absorbent of glue formulations, andconsequently may have a greater glue requirement and total glue cost,such as by about two-fold, to achieve satisfactory fixing of the printedsheets to articles.

In embodiments, the cut-to-print registration variance can be from lessthan or equal to about 30 thousandths of an inch, for example, less thanor equal to about {fraction (1/32)} inch, and each printed sheet canhave the same length and width dimensions as the other printed sheets inthe stack to within a variance of less than about 5 thousandths of aninch. In embodiments, the cut-to-print registration variance can be fromabout 0.03 to about 0.015 inches, that is about 30 thousandths of aninch to about 15 thousandths of an inch, for example, from about{fraction (1/32)} inch to about {fraction (1/64)} inch, and each printedsheet can have the same length and width dimensions as the other printedsheets in the stack to within a variance of, for example, from about0.001 to about 0.005 inches, or from about 1 thousandth of an inch toabout 5 thousandths of an inch.

In embodiments, the band around the stack can encompass a portion of twoopposite sides including the full height of the stack, and a portion ofthe outer facing top and bottom sheets of the stack including the fullwidth of the stack.

In embodiments, two opposite sides of the stack can be parallel where,for example, the bundle resembles a cube comprised of square sheets, orfor example, where the bundle resembles a parallelepiped or arectangular block comprised of rectangular sheets. In embodiments, twoopposite sides are other than parallel (i.e., not parallel), forexample, where the bundle is other than a cube or parallelepiped. Thebundle can have a unitary shape or uniform shape but for the irregularshape of the constituent sheets. Thus, because of the high uniformity orsimilarity of sheet-to-sheet dimensions the resulting bundle formed fromirregularly shaped stacked sheets can also have high dimensionaluniformity in the x-, y-, and z-directions. Bundles can have at leastone set of non-parallel opposite sides, such as where sheets have anirregular shape, for example, sheets having a bow-tie shaped outline,such as in an arbitrary x-y plane, sheets having a paisley shape, sheetshaving a tear-drop shape, sheets having a lightening bolt shape, andlike irregular shapes. Other sheet shapes can include, for example,circles, ovals, square or rectangular sheets having square corners,rounded corners, or angled corners. It will be readily apparent thatcertain sheet shapes can have parallel edges yet still appear irregular,such as a sheet having saw-tooth or diagonal cut-out pattern on one ormore edges. It is also readily evident that sheet edges of the sheetswhen stacked (compounded) become part of the sides of the stack orbundle. It will also be apparent that sheets can be made which includeperforations, for example, for preparing labeled articles with adetachable label portion.

The ends of a band around the stack can preferably overlap each otherand the overlap portion can preferably include a point of attachment.The point of attachment can be accomplished, for example, with anadhesive, a weld, a crimp, Velcro®, and like fastening or joiningtechniques, or combinations thereof. The band can be any suitablebinding material, such as plastic, paper, metal, rubber, elastomer,string, and like materials, or combinations thereof. The bundle ofprinted sheets can have, in embodiments, for example, from 1 to 5 bands,or more. In embodiments, for example, where the bundle of sheets is longand rectangular the bundle can have 2 to more bands, such as 2 to 3bands. In embodiments, for example, where the bundle and its stackedsheets are relatively stable against skewing without a band or wherecost or use considerations suggest, one or a single band around thebundle can suffice to maintain a useful and unitary shape of the bundle.

The overwrapper can be, for example, any suitable wrapper material orshrink-wrap material, such as clear, translucent, or opaque materialsincluding but not limited to natural or synthetics, such as plastic,paper, and like materials, or combinations thereof. The overwrapper onthe banded stack can include one or more pull-tab or tear-strip tofacilitate removal of the overwrapper from the bundle. In embodiments,the overwrapper on the banded stack can completely enclose the bundle.In other embodiments, the overwrapper on the banded stack incompletelyencloses the bundle, for example, having open-end regions or open-sideregions, or for example where the overwrapper does not cover all or asubstantial portion of the stack covered by a band.

In embodiments, although not required, the bundles can include, ifdesired, a chipboard, a stiffener panel, or combinations thereof, seefor example U.S. Pat. No. 4,830,186, assigned to Xerox Corp., to providefor example, a removal support structure to stabilize the stack orbundle from inadvertently skewing or toppling during handling or use.For reasons mentioned above, the bundled printed sheets of the presentdisclosure are preferably free of a chipboard, a stiffener panel, orlike articles.

In embodiments, bundles of printed sheets can be prepared, if desired,with a band but without an overwrapper and still retain their unitaryshape, cut-to-print registration variance, with individual sheets havingthe same length and width dimensional variance as the other printedsheets in the stack or bundle. Each sheet can have substantially thesame x- and y-dimensions as all other sheets in the stack, for example,as measured in an x-y plane. The “same x and y dimensions” refers tosheet-to-sheet uniformity of the x-dimension and the y-dimension. Inembodiments, the x- and y-dimensions for each sheet can be the same(x=y), such as a square sheet. In embodiments, the x- and y-dimensionsfor each sheet can be different (x≠y), such as a rectangular sheet. Inembodiments, the x-dimension for each sheet can be substantially thesame to provide a stack having sheets all having the same variation inthe x-dimension, for example, a sheet having an irregular x-dimension.In embodiments, the y-dimension for each sheet can be substantially thesame to provide a stack having sheets all having about the samevariation in the y-dimension, for example, a sheet having an irregulary-dimension. In embodiments, the x- and the y-dimensions for each sheetcan vary to provide a stack or bundle having sheets which all have aboutthe same variation in the x- and y-dimensions, for example, a sheethaving irregular x- and y-dimensions. The present disclosure inembodiments, provides bundles of printed sheets where the individualsheets can have a variety of shapes, for example, square, diamond,heart, rectangular, circular, oval, triangular, and like regular shapesor irregular shapes. The present disclosure in embodiments, providesbundles of printed sheets where the sheets can have, for example, aregular or an irregular shape, such as irregular or non-uniformdimensions, but where all the sheets in the bundle have substantiallythe same shape and dimensions as all other sheets in the bundle. Eachsheet in the bundle preferably has substantially the same orientation inan arbitrary orthogonal x-y-z coordinate system. Each sheet preferablyoccupies an x-y plane and the sheets are stacked one-on-top anotherabout the z-axis in the orthogonal x-y-z coordinate system or Cartesiancoordinate system, that is having right angles between each axis.“Cartesian coordinate system” refers to any of three coordinates (x-y-z)that locate a point in space and measure its distance from any of threeintersecting coordinate planes (x-y-z planes) measured parallel to thatone of three straight-line axes, that is, the intersection of the othertwo planes.

In embodiments, an apparatus for making bundled printed sheets of thedisclosure can comprise:

-   -   a printable web;    -   a print module to print on the printable web;    -   a cutter module to cut the printed web into a stream of printed        sheets and a waste matrix;    -   a collator module to collate each stream of printed sheets into        a registered stack;    -   a conveyor module to convey each registered stack into a stack        stream; and    -   a packaging module to package each registered stack in the stack        stream into a package containing bundled printed sheets,    -   wherein, for example,    -   the printable web and the print module can be a high speed        lithographic press adapted to:        -   print and cure multiple color UV curable inks on a paper            substrate;        -   apply a protective coating;        -   chill the protectively coated web; and        -   apply an antistatic coating;    -   the cutter module can be a rotary die-cutter adapted to        angle-cut the printed web, the cutter further including a static        eliminator to facilitate sheet and matrix separation;    -   the collator module can be a sheet stream transporter and        batch-stacker to transport and collate each stream of printed        sheets from the cutter module into a registered stack;    -   the conveyor module can be a conveyor for each batch-stacker and        adapted to directly receive the stack batch and transport the        stack batch as a single stack stream to the packaging module;    -   each of the bundle of printed sheets can have from about 10 to        about 1,500 cut printed sheets, each printed sheet can have a        narrow cut-to-print registration variance of, for example, from        less than or equal to about 0.03 inches, and each printed sheet        can have the same length and width dimensions as the other        printed sheets in the bundle to within a variance of, for        example, less than or equal to about 0.005 inches; and    -   the packaging module can include, for example, a banding        machine, an overwrapping machine, a heat-shrink machine, a        containerizer machine, a stretch banding machine, a palletizer,        or combinations thereof; and    -   the apparatus additionally having an humidity controller, a        web-nip just before the chiller module, and a web-nip just        before the cutter module.

In embodiments, each registered stack can be vertical or horizontal.Preferably, each registered stack is formed in a vertical orientation,that is, having sheets stacked or layered on top of one another andwhich verticality can avoid the need for additional structural supports,that is, the stacks are preferably unsupported. The printable web andthe print module in combination, in embodiments, can comprise a highspeed offset printing press. “High speed” refers to, for example, alinear speed of from about 300 to about 1,200 feet per minute or more.The cutter module of the apparatus can comprise a rotary die-cutter, aflat-bed die-cutter, a slit-and-gap cutter, a slit-and-but cutter, aguillotine cutter, or combinations thereof. In a preferred embodiment,the cutter module comprises a rotary die-cutter adapted to angle-cut theprinted web into at least one sheet stream and a waste matrix. Theangle-cut can be, for example, as shown in FIGS. 8C or 8D, andpreferably as shown in FIG. 8D.

In embodiments, for example, in high volume applications such as highspeed offset, the printable web can have a relatively wide width and arelatively high speed, such as a width from about 16 to about 40 inchesand a linear speed of from about 300 to about 900 feet per minute, ormore. In other embodiments, for example, in lower volume applicationssuch as certain flexography applications, the printable web or substratecan have a relatively narrow width and relatively slow speed, such as awidth of less than about 18 inches and a speed of less than 400 feet perminute, such as from about 10 to less than about 300 feet per minute. Inother embodiments, for example, in mid-volume applications, theprintable web or sheet feeding can have a relatively narrower width andfaster speed, such as a width of less than about 16 inches and a speedof from about 200 to less than about 500 feet per minute. In still otherembodiments, for example, high-speed narrow-width offset applications,the printable web can have a relatively narrow width and relatively fastspeed, such as a width of less than about 20 inches, and a speed of fromabout 300 to about 1,200 feet per minute.

In embodiments, the conveyor module can comprise an endless belt, suchas one or more belts, or like transport devices. In embodiments, theconveyor module can comprise a first conveyor having two over-underparallel endless belts and an elevator, and a second conveyor, whereinthe two over-under parallel endless belts each carry a stack stream fromthe collator to the second conveyor, the elevator being operable toalternate the position of the two over-under parallel endless beltsrelative to the collator and the second conveyor. The conveyor modulecan be configured so that each stack stream on the first conveyor ismerged or combined into a single stack stream on the second conveyor.Other suitable conveyor module configurations are readily apparent andcan depend on, for example, convenience, throughput, cost of operation,cost and speed of packing equipment, and like considerations. Thus, inone configuration, a second conveyor can convey the stack streamuni-directionally to the packaging module. In another alternativeconfiguration, the second conveyor can convey the stack streambi-directionally to two separate packaging modules, that is, the mergedstack stream on the second conveyor provides two stack streamsalternately flowing in opposite directions from the second conveyor totwo separate pack lines, as illustrated and discussed in FIG. 7.

In embodiments, the packaging module can comprise a first bandingstation, a second over-wrapping station, and an optional thirdshrink-wrapping station. This packaging module can further optionallycomprise a containerizer module having, for example, a boxing station, abox sealing station, or both. In embodiments, the packaging module cancomprise a first banding station for making bundled printed sheets whichapplies a band around each stack of printed sheets, and a containerizermodule, such as a boxing station, where the bundled printed sheets areboxed in a box having a sealable liner. In embodiments, thecontainerizer module, such as a boxing station, can be adapted to wrap acontainer material around a plurality of bundles (bundle of bundles),such as cardboard stock or plastic, to form the container in-line.In-line container formation has a number of advantages includingjust-in-time container generation, automatic or robotic handling,reduced space requirement for containers prior to filing, and likeadvantages.

In embodiments, the apparatus can further comprise a debris collectorsituated near, such as for about 0.1 inch to about 36 inches, the cuttermodule. The debris collector can be, for example, a vacuum take-off ormanifold, a non-contact tacky-surface roller, a contact tacky-surfaceroller, a disturber brush member, or combinations thereof. The debriscan be, for example, ambient dust or dust created from the cutting, web-or sheet transport, printing, coating, treating, jogging, and likemanipulations of the substrate, before or after cutting. Thus, themethod can further include removing debris, such as paper or plasticdust or cuttings already present on the web or fed-sheets or generatedfrom cutting or manipulating the web- or fed-sheets into cut printedsheets.

In embodiments, the printable web can be comprised of, for example,paper, film, synthetic materials, foils, metalized version thereof, andlike materials, or combinations thereof. A preferred printable webmaterial for economy and versatility is, for example, rolled paper orrolled plastic film.

In embodiments, the apparatus can further comprise an ambient humiditycontrol system, for example, having a localized spray or mist nozzle orhaving a large scale humidity environmental control systems capable ofambient humidity control over one or more production systems or modulesof the disclosure. Although not required the method of making bundledprinted sheets is preferably accomplished in a controlled environment,such as where ambient humidity and temperature can be regulated, tosafe-guard the quality of the processes and the products. “Ambienthumidity” refers to the humidity of the immediate atmosphere, whichsurrounds the apparatus, particularly in the cutting and stackingoperations where static charge, frictional charge, or streaming chargegeneration or accumulation may occur. The methods of making bundledprinted sheets of the disclosure can be accomplished over a range ofrelative humidity conditions although very low humidity conditions, suchas below about 25 percent are contraindicated, especially in the absenceof alternative methods of static charge suppression or elimination inweb-based production systems. The sensitivity of the methods of makingto ambient humidity can depend upon many factors, such as temperature,barometric pressure, operating speed(s), web or sheet substrate typeselected (e.g., paper, plastic, etc.), the printing inks selected andthe amounts applied, coating or other treatment formulations selectedand the amounts applied, and like considerations. In embodiments, asuitable relative humidity range for use in the methods of making whichemploy a paper web or paper fed-sheets is, for example, from about 50 toabout 80 percent, and a preferred relative humidity range is from about65 to about 75 percent. Methods for controlling ambient humidity areknown, such as HVAC climate-controlled facilities, local application ofa humidifier, intermittent water-mist sprayers, and like humidificationmethods. It will be readily understood by one of ordinary skill in theart that the humidity requirements and humidity sensitivity of theapparatus and process of the disclosure can depend upon the print engineor print technologies selected and can even depend upon the differentconfigurations of the same print engine. For example, high-speed offsetmethods generally tend to favor higher humidity conditions whilexerographic methods generally tend to favor lower humidity conditions.

In embodiments, the apparatus and method of making of the disclosure arepreferably maintained at, or accomplished at, an ambient temperature offrom about 50 to about 90 degrees ° C.

In embodiments, the apparatus can further comprise a web coating module.The web coating module can be configured to apply one or more coatingsto either or both sides of the web after the print module. Coatingswhich can be applied to the printed web, or prior to printing on theweb, and can include, for example, a varnish coating, a gloss coating, aprotective coating, an anti-static coating, an opaque coating forexample to conceal printed images beneath such as in some scratch-offgame cards, and like coatings, or combinations thereof. In embodiments,in-line high gloss UV varnish application to a continuous web-basedsubstrate can provide considerable savings, for example, in time, steps,set-up, handling, rework, discards, and like savings.

In embodiments, the apparatus can further include a web-chiller module.The web-chiller module can be situated anywhere along the web's path,for example, between the print module and the cutter module, andpreferably just after the in-line coating station or web coating module.The web-chiller module provides a convenient way to, for example, removeexcess latent heat from the web arising from one or more printingoperations, UV light exposure or curing, frictional contact with webpropulsion or guidance devices, and like sources of heating.

In embodiments, the apparatus can further include a web nip situatedbetween a nip roller and a backing roller, the web-nip preferably beingsituated just before the chiller in the chiller module 13 c and asdiscussed and illustrated in FIG. 1. In embodiments, the apparatus canfurther include a web-nip between a nip roller and an anvil roller. Thisweb-nip can preferably be situated just before the cutter in the cuttermodule as illustrated and discussed in FIG. 4B.

In embodiments, the cutter module can provide from 2 to about 80 streamsof printed sheets, the collator can provide from 2 to about 80registered stacks corresponding to the number of collated sheet streams,and the conveyor module can convey from 2 to 80 registered stack streamsinto a single stack stream. Alternatively, the conveyor module canconvey from 2 to 80 registered stack streams into two stack streams. Inembodiments, the packaging module can comprise an optional stack jogger,a stack bander, an optional stack overwrapper, and an optionalcontainerizer. The containerizer can comprise, for example, a person ordevice for placing the bundled printed sheets within a container, forsealing the container, and optionally placing a plurality of sealedcontainers on a carrier. For example, a manual operator, a programmableindustrial grade robot, or like devices, can be programmed topick-and-place the bundled printed sheets into a container, such as abox or carton, and thereafter seal the container, and optionally place aplurality of the sealed containers on a carrier, such as a pallet orskid, and thereafter optionally overwrap the plurality of containers onthe carrier with stretch banding to prevent containers from separatingfor the others or to prevent containers from falling off the carrier.

In embodiments, the package can comprise a bundled printed sheetscomprising: a plurality of printed sheets in a stack; a band around thestack; and an optional overwrapper on the banded stack, each printedsheet having a narrow cut-to-print registration variance, for example,of from less than or equal to about 0.03 inches, and each printed sheethaving the same length and width dimensions as the other printed sheetsin the stack to within a variance of less than or equal to about 0.005inches; and a container for the bundled printed sheets. The package canfurther comprise a plurality of the containers on a pallet, theplurality of containers optionally being partially overwrapped with anoverwrapper.

In embodiments, the present disclosure provides a sheet-fed basedapparatus for making bundled printed sheets, comprising, for example, asheet feeder; a print module to print on the fed-sheets; a cutter moduleto cut the printed fed sheets into a stream of cut printed sheets; acollator to transport and collate each stream of cut printed sheets intoa registered stack; a conveyor module to convey each registered stackinto a stack stream; and a packaging module which packages eachregistered stack in the stack stream into a package having a bundledprinted sheets. In embodiments of the sheet-fed apparatus, thesheet-feeder and the print module in combination can comprise, forexample, a high-speed sheet-fed print engine. The cutter module cancomprise, for example, a rotary die-cutter to angle-cut the printedsheets into at least one sheet stream and a waste matrix. The packagingmodule can comprise, for example, an optional stack jogger, a stackbander, an optional stack overwrapper, an optional source of heat energyto shrink the overwrapper if desired, and an optional containerizer. Thepackage can further comprise a plurality of containerized bundledprinted sheets.

In embodiments, the present disclosure provides a method of makingbundled printed sheets, comprising:

-   -   printing on a printable web;    -   cutting the printed web into a stream of printed sheets and a        waste matrix;    -   collating each stream of printed sheets into a registered stack;    -   conveying each registered stack into a stack stream; and    -   packaging each registered stack in the stack stream to form a        bundle of printed sheets.

In embodiments the apparatus and method of making can employ a rotarydie-cutter which cuts printed sheets from the web, which printed sheetsprior to cutting can be, aligned adjacent sheets, staggered adjacentsheets, angle-cut adjacent sheets, or combinations thereof.

In embodiments, the method of making steps, such as printing, cutting,collating, conveying, and packaging, can preferably be accomplishedcontinuously. “Continuously,” “continuous,” or like terms, in thiscontext refer to non-stop operation during a job, or withoutinterruption, for example, for a period of from about 10 minutes toabout 1,000 hours or more. In embodiments, the method and apparatus arecapable of operating non-stop or without interruption for extendedperiods of time such, as 24/7 for up to a month and beyond, when forexample, web- or fed-sheet stock, inks, coatings, surface treatmentmaterial or agents, banding materials, wrapping materials, and the likeconsumables, can be replenished as needed to sustain the continuousoperation and production of printed sheets and the resulting bundles. Inembodiments, the method of making bundled printed sheets of the presentdisclosure is highly efficient and can provide continuous manufacture ofbundled printed sheets in relatively high volumes, starting from theuncoated or untreated web- or fed-sheet stock to the bundled andpackaged printed sheets, for example, in from about 1 to about 10minutes, preferably from about 1 to about 8 minutes, and more preferablyfrom about 1 to about 6 minutes, to go from paper roll feed stock to aboxed bundle.

The printed sheets can be used for, but are not limited to, for example,labels, business cards, greeting cards, trading cards, tickets, gamecards, bank cards, phone cards, identification cards, note pad sheets,paper currency, negotiable instruments, interlaced images, coupons,chits, ballots, maps, forms, time sheets, and like applications, orcombinations thereof. The printed sheets can be used in, but are notlimited to, a variety of applications including, for example, individualproduct labels, such as used on beverage containers or canned goods,signage, bumper stickers, and like applications.

In embodiments the present disclosure provides a method of makingbundled printed sheets, comprising:

-   -   printing on a printable web;    -   die-cutting the printed web into a stream of printed sheets and        a waste matrix;    -   collating each stream of printed sheets into a vertical        registered stack;    -   conveying each registered stack into a single stack stream;    -   banding each registered stack in the conveyed single stack        stream to form a banded stack of bundled printed sheets wherein        a band circumscribes a portion of two opposite sides and the        entire height of the vertical stack and a portion of the width        of the first sheet and a portion of the width of the last sheet        in the stack;    -   overwrapping each banded stack; and    -   optionally placing each overwrapped banded stack in a container.

Similarly, in embodiments the present disclosure provides a method ofmaking bundled printed sheets from single-sheets or fed-sheets,comprising:

-   -   providing single-sheets;    -   optionally printing on the single-sheets with a print engine;    -   cutting each printed single-sheet into a stream of cut-printed        sheets and a waste matrix;    -   collating each stream of cut-printed sheets into a registered        stack;    -   conveying each registered stack into a stack stream; and    -   packaging each registered stack in the stack stream into a        bundle of printed sheets.

In embodiments, the provided single-sheets can be, for example, free ofprinted images or have printed images on one or both faces of the sheet.As mentioned with other embodiments for methods of making of the presentdisclosure, the cutting can be preferably accomplished by die-cutting.The die-cutting can preferably be accomplished with an angle-cut rotarydie-cutting machine. In other embodiments, the cutting can beaccomplished using slit-and-gap cutting methods. “Slit-and-gap” cuttinggenerally refers to cutting which is capable of slitting and cutting-outor creating a gap between adjacent sheets or work pieces in the processdirection.

In embodiments the present disclosure provides a method of affixingprinted sheets to articles, comprising:

-   -   optionally slitting the over-wrapper on an over-wrapped bundle        of printed sheets;    -   removing the over-wrapping from over-wrapped bundled printed        sheets comprising:    -   a plurality of printed sheets in a stack;    -   a band around the stack; and    -   an overwrapper on the banded stack, each printed sheet having a        narrow cut-to-print registration variance of from less than or        equal to about {fraction (1/16)}^(th) inch, and each printed        sheet having the same length and width dimensions as the other        printed sheets in the stack to within a narrow variance of less        than or equal to about {fraction (1/100)}^(th) inch;    -   optionally fanning the unwrapped bundled printed sheets;    -   removing the banding from the unwrapped bundled printed sheets;    -   inserting the stacked printed sheets into a sheet applicator        machine;    -   optionally activating an adhesive on, or applying an adhesive to        a portion of the individual printed sheets; and    -   contacting the individual printed sheets with an article.

In embodiments, the present disclosure provides an article having aprinted sheet attached thereto prepared by the abovementioned method ofaffixing printed sheets to articles. In embodiments, the presentdisclosure provides an article having a printed sheet attached thereto,the printed sheet being obtained from unpackaging a bundle of printedsheets of the disclosure comprising a plurality of printed sheets in astack having a band around the stack and an overwrapper on the bandedstack, and affixing the printed sheet to the article with a labelapplicator machine.

In embodiments the present disclosure provides a stack of printedsheets, comprising: a plurality of printed sheets in a unitary form,each printed sheet having a narrow cut-to-print registration variance,for example, of from less than or equal to about 0.03 inches, and eachprinted sheet having the substantially same length and width dimensionsas the other printed sheets in the stack to within a narrow variance ofless than or equal to about 0.005 inches, and the stack being situatedin a label applicator machine.

In embodiments, the printed sheets of the stack can be product labelshaving product collateral information, images, text, and like markings,or combinations thereof, printed thereon. The stack of printed sheetscan be a unitary form such as a parallelepiped, having for example, allsquare corners of about 90 degrees, such as a cube or an elongated cube.A cube has substantially identical length, width, and height dimensions.An elongated cube may have one, two, or three of its length, wide, orheight dimensions being different from one another.

In embodiments the present disclosure provides an article having aprinted sheet attached thereto, the printed sheet being obtained fromunpackaging a bundle of substantially identically shaped printed sheets,the bundle of printed sheets comprising:

-   -   a plurality of printed sheets in a stack;    -   a band around the stack; and    -   an overwrapper on the banded stack,    -   each printed sheet having a narrow cut-to-print registration        variance of, for example, from less than or equal to about        {fraction (1/16)}^(th) inch, and each printed sheet having        substantially the same length and width dimensions as the other        printed sheets in the stack to within a narrow variance of, for        example, less than or equal to about {fraction (1/100)}^(th)        inch.

Methods for manufacturing labels, such as self-adhesive labels, for usein a label applicator machines are known, see for example, U.S. Pat. No.6,273,987. Label applicator machines and methods for applying labels toarticles or containers are known, see for example, U.S. Pat. No.4,793,891. U.S. Pat. No. 4,798,648, discloses an article-feeding devicefor use in a label applicator machine, and also discloses formingadhesive labels by die-cutting from a web, intermediate transfer of thecut labels, and application of the labels to articles. High speed labelapplicator machines for high volume solutions using hot melt adhesives,cold adhesives, pressure sensitive adhesives, or combinations thereof,and conveyor equipment are also commercially available from, forexample, Abacus Label Applications, Maple Ridge, B.C. Canada(www.abacuslabel.com).

All publications, patents, and patent documents are incorporated byreference herein in their entirety, as though individually incorporatedby reference. The disclosure has been described with reference tovarious specific and preferred embodiments and techniques. However, itshould be understood that many variations and modifications can be madewhile remaining within the spirit and scope of the disclosure.

1. A bundle of printed sheets, comprising: a plurality of printed sheetsin a stack; a band around the stack; and an overwrapper on the bandedstack, each printed sheet having a cut-to-print registration variance offrom less than or equal to about 0.03 inches, and each printed sheethaving the same length and width dimensions as the other printed sheetsin the stack to within a variance of less than or equal to about 0.005inches.
 2. The bundle of printed sheets of claim 1 wherein thecut-to-print registration variance is from about 0.03 to about 0.015inches.
 3. The bundle of printed sheets of claim 1 wherein each printedsheet having the same length and width dimensions as the other printedsheets in the stack is to within a variance of from about 0.001 to about0.005 inches.
 4. The bundle of printed sheets of claim 1 wherein theband around the stack encompasses a portion of two opposite sidesincluding the full height of the stack, and a portion of the outerfacing top and bottom sheets including the full width of the stack. 5.The bundle of printed sheets of claim 4 wherein the two opposite sidesare parallel.
 6. The bundle of printed sheets of claim 4 wherein the twoopposite sides are other than parallel.
 7. The bundle of printed sheetsof claim 1 wherein the ends of a band around the stack overlap eachother and the overlap portion includes a point of attachment.
 8. Thebundle of printed sheets of claim 7 wherein the point of attachment isaccomplished with an adhesive, a weld, a crimp, or combinations thereof.9. The bundle of printed sheets of claim 1 wherein the band is plastic,paper, metal, rubber, string, or combinations thereof.
 10. The bundle ofprinted sheets of claim 1 having 1 to 5 bands.
 11. The bundle of printedsheets of claim 1 having 2 bands.
 12. The bundle of printed sheets ofclaim 1 having 1 band.
 13. The bundle of printed sheets of claim 1wherein the overwrapper on the banded stack includes a pull-tab tofacilitate removal of the overwrapper from the bundle.
 14. The bundle ofprinted sheets of claim 1 wherein the overwrapper on the banded stackcompletely encloses the bundle.
 15. The bundle of printed sheets ofclaim 1 wherein the overwrapper on the banded stack incompletelyencloses the bundle.
 16. The bundle of printed sheets of claim 1 whereinthe bundle has from about 10 to about 10,000 printed sheets.
 17. Thebundle of printed sheets of claim 1 wherein the bundle has from about 50to about 5,000 printed sheets.
 18. The bundle of printed sheets of claim1 wherein the bundle has from about 50 to about 1,500 printed sheets.19. The bundle of printed sheets of claim 1 wherein the bundle is freeof a chipboard support or stiffener panel.
 20. The bundle of printedsheets of claim 1 further comprising a chipboard, a stiffener panel, orcombinations thereof.
 21. The bundle of printed sheets of claim 1wherein the bundle is from about 1 to about 2 inches wide, about 2 toabout 4 inches high, and about 3 to about 10 inches long.
 22. A bundleof printed sheets, comprising: a plurality of printed sheets in a stack;a band around the stack; and each printed sheet having a cut-to-printregistration variance of from less than or equal to about 0.03 inches,and each printed sheet having the same length and width dimensions asthe other printed sheets in the stack to within a variance of less thanor equal to about 0.005 inches.
 23. An apparatus for making bundledprinted sheets, comprising: a printable web; a print module to print onthe printable web; a cutter module to cut the printed web into a streamof printed sheets; a collator module to collate each stream of printedsheets into a registered stack; a conveyor module to convey eachregistered stack into a stack stream; and a packaging module to packageeach registered stack in the stack stream into a package comprised of abundle of printed sheets.
 24. The apparatus of claim 23 wherein theregistered stack has a plurality of printed sheets.
 25. The apparatus ofclaim 23 wherein each registered stack is vertical.
 26. The apparatus ofclaim 23 wherein each registered stack is unsupported.
 27. The apparatusof claim 23 wherein the printable web and the print module, incombination, comprise a high-speed offset printing press.
 28. Theapparatus of claim 23 wherein the cutter module comprises a rotarydie-cutter, a flat-bed die-cutter, a slit-and-gap cutter, a slit-and-butcutter, a guillotine cutter, or combinations thereof.
 29. The apparatusof claim 23 wherein the cutter module comprises a rotary die-cutter toangle-cut the printed web into at least one sheet stream and a wastematrix.
 30. The apparatus of claim 23 wherein the printable web has awidth of from about 16 to about 40 inches and a speed of from about 300to about 1,200 feet per minute.
 31. The apparatus of claim 23 whereinthe printable web has a speed of from about 300 to about 900 feet perminute.
 32. The apparatus of claim 23 wherein the printable web has awidth of less than about 16 inches and a speed of from about 10 feet perminute to less than about 300 feet per minute.
 33. The apparatus ofclaim 23 wherein the printable web has a speed of from about 10 feet perminute to less than about 300 feet per minute.
 34. The apparatus ofclaim 23 wherein the conveyor module comprises an endless belt.
 35. Theapparatus of claim 23 wherein the conveyor module comprises a conveyingelevator, the elevator being operable to receive a batch of stacks fromtwo or more batch stackers and to convey the received batch of stacks toa first conveyor.
 36. The apparatus of claim 35 wherein first conveyorconveys the batch of stacks as a stack stream uni-directionally to thepackaging module.
 37. The apparatus of claim 36 wherein first conveyorconveys the batch of stacks as a stack stream bi-directionally to two ormore packaging modules.
 38. The apparatus of claim 23 wherein thepackaging module comprises a first banding station, a secondover-wrapping station, and an optional third shrink-wrapping station.39. The apparatus of claim 38 wherein the packaging module furthercomprises a boxing station and box sealing station.
 40. The apparatus ofclaim 23 wherein the packaging module comprises a first banding stationfor making bundled printed sheets, and a boxing station.
 41. Theapparatus of claim 40 wherein the boxing station manually orautomatically places the bundled printed sheets in a box having asealable liner.
 42. The apparatus of claim 23 further comprising adebris collector near the cutter module.
 43. The apparatus of claim 23wherein the printable web comprises paper, film, synthetic materials,metalized papers, foils, and combinations thereof.
 44. The apparatus ofclaim 23 wherein each stream of printed sheets is transported from thecutter to the collator with at least one transport belt and at least onebacking roller opposing the transport belt.
 45. The apparatus of claim23 further comprising an ambient humidity control system.
 46. Theapparatus of claim 23 further comprising a web coating module.
 47. Theapparatus of claim 46 wherein the web coating module applies to the web,after the print module, a varnish coating, a gloss coating, a protectivecoating, an anti-static coating, or combinations thereof.
 48. Theapparatus of claim 47 further comprising a web chiller module betweenthe web coating module and the cutter module.
 49. The apparatus of claim48 further comprising a web nip between a nip roller and a backingroller just before the chiller in the chiller module.
 50. The apparatusof claim 23 further comprising a web nip between a nip roller and ananvil roller just before the cutter in the cutter module.
 51. Theapparatus of claim 23 wherein the cutter module provides from 2 to 80streams of printed sheets.
 52. The apparatus of claim 23 wherein thecollator provides from 2 to 80 registered stacks.
 53. The apparatus ofclaim 23 wherein the conveyor module conveys from 2 to 80 registeredstack streams into a single stack stream.
 54. The apparatus of claim 23wherein the conveyor module conveys from 2 to 80 registered stackstreams into two stack streams.
 55. The apparatus of claim 23 whereinpackaging module comprises an optional stack jogger, a stack bander, anoptional stack overwrapper, and an optional containerizer.
 56. Theapparatus of claim 23 wherein the containerizer comprises a person ordevice for placing the bundled printed sheets into a container, forsealing the container, and optionally placing a plurality of sealedcontainers on a carrier.
 57. The apparatus of claim 23 wherein thepackage comprises: a bundle of printed sheets comprising: a plurality ofprinted sheets in a stack; a band around the stack; and an optionaloverwrapper on the banded stack, each printed sheet having acut-to-print registration variance of from less than or equal to about{fraction (1/16)}^(th) inch, and each printed sheet having the samelength and width dimensions as the other printed sheets in the stack towithin a variance of less than or equal to about {fraction (1/100)}^(th)inch; and a container for the bundle of printed sheets.
 58. Theapparatus of claim 57 the package further comprising: a plurality of thecontainers on a pallet optionally partially overwrapped with anoverwrapper.
 59. The apparatus of claim 23 wherein the cutter moduleincludes a static eliminator.
 60. An apparatus for making bundledprinted sheets, comprising: a sheet feeder; a print module to print onthe fed sheets; a cutter module to cut the printed fed sheets into astream of cut printed sheets; a collator to collate each stream of cutprinted sheets into a registered stack; a conveyor module to convey eachregistered stack into a stack stream; and a packaging module whichpackages each registered stack in the stack stream into a package havinga bundled printed sheets.
 61. The apparatus of claim 60 wherein thesheet feeder and the print module in combination comprise a high speedsheet-fed print engine.
 62. The apparatus of claim 60 wherein the cuttermodule comprises a die-cutter to angle-cut the printed sheets into atleast one sheet stream and a waste matrix.
 63. The apparatus of claim 60wherein packaging module comprises an optional stack jogger, a stackbander, an optional stack overwrapper, and an optional containerizer.64. The apparatus of claim 60 wherein the package further comprises aplurality of containerized bundled printed sheets.
 65. The apparatus ofclaim 23 wherein the print module comprises a first print engine toprint constant image information, and a second print engine to printvariable image information.
 66. A method of making bundled printedsheets, comprising: printing on a printable web; cutting the printed webinto a stream of printed sheets and a waste matrix; collating eachstream of printed sheets into a registered stack; conveying eachregistered stack into a stack stream; and packaging each registeredstack in the stack stream to form a bundle of printed sheets.
 67. Themethod of claim 66 wherein cutting is accomplished with rotarydie-cutter, a flat-bed die-cutter, a slit-and-gap cutter, aslit-and-butt cutter, a guillotine cutter, or combinations thereof. 68.The method of claim 66 wherein cutting is accomplished with a rotarydie-cutter.
 69. The method of claim 68 wherein the die-cutter angle-cutsthe printed web into a stream of printed sheets.
 70. The method of claim68 wherein the die-cutter angle-cuts the printed web into from 2 to 80streams of printed sheets.
 71. The method of claim 66 wherein theprintable web has a width of from about 16 to about 40 inches and aspeed of from about 300 to about 900 feet per minute.
 72. The method ofclaim 66 wherein the printable web has a speed of from about 300 toabout 1,200 feet per minute.
 73. The method of claim 66 wherein theprintable web has a width of less than about 16 inches and a speed offrom about 10 to less than about 300 feet per minute.
 74. The method ofclaim 66 wherein the printable web has a speed of from about 10 to lessthan about 300 feet per minute.
 75. The method of claim 66 whereinconveying conveys from 2 to 80 stack streams into a merged singlestream.
 76. The method of claim 75 further comprising conveying themerged single stream in different directions into two separate stackstreams.
 77. The method of claim 66 wherein the printing, cutting,collating, conveying, and packaging, are accomplished continuously. 78.The method of claim 66 wherein the printing comprises offset,lithography, flexography, gravure, non-impact printing methods,electrophotography, and combinations thereof.
 79. The method of claim 66wherein the printable web comprises paper, film, a synthetic material, ametalized synthetic material, a metalized paper, a foil, andcombinations thereof.
 80. The method of claim 66 wherein each cuttingevent of the printed web is perpendicular to the web process direction.81. The method of claim 66 wherein cutting is accomplished with adie-cutter.
 82. The method of claim 66 wherein cutting is accomplishednon-simultaneously and non-perpendicular to the web process-directionwith a die-cutter.
 83. The method of claim 81 wherein the die-cuttercuts from the web printed sheets which are, prior to cutting, alignedadjacent sheets, staggered adjacent sheets, angle-cut adjacent sheets,and combinations thereof.
 84. The method of claim 83 wherein die-cuttingcuts aligned adjacent printed sheets widthwise across the webprocess-direction.
 85. The method of claim 83 wherein die-cutting cutsstaggered adjacent printed sheets widthwise across the webprocess-direction.
 86. The method of claim 83 wherein die-cutting cutsangle-cut adjacent sheets widthwise across the web process-direction.87. The method of claim 66 wherein each cutting event produces from 2 to50 of individually cut and printed sheets widthwise across the webprocess-direction.
 88. The method of claim 66 wherein die-cutting theprinted web continuously produces a stream of printed sheets.
 89. Themethod of claim 66 wherein collating is accomplished by a collatorhaving a receiver for receiving and registering each stream of printedsheets into an incipient registered stack.
 90. The method of claim 66wherein collating a number of streams of printed sheets produces anequal number of registered stacks of printed sheets.
 91. The method ofclaim 66 wherein a registered stack or a bundle of printed sheets hasfrom about 10 to about 5,000 printed sheets.
 92. The method of claim 66wherein a registered stack or a bundle of printed sheets has from about10 to about 1,500 printed sheets.
 93. The method of claim 66 whereineach registered stack has cut printed sheets stacked vertically andunsupported.
 94. The method of claim 66 wherein each registered stackhas cut printed sheets stacked vertically and supported.
 95. The methodof claim 66 wherein each registered stack has cut printed sheets stackedhorizontally and supported.
 96. The method of claim 66 wherein eachregistered stack is edge-to-edge registered, side-to-side registered,height-registered, edge-registered, width-registered, weight registered,or combinations thereof.
 97. The method of claim 66 wherein eachregistered stack is height registered and edge-to-edge registered. 98.The method of claim 66 wherein each registered stack is edge-to-edgeregistered.
 99. The method of claim 66 wherein conveying conveys on afirst conveyor the registered stacks away from the collator in the webprocess-direction for a distance and thereafter the registered stacksare displaced laterally, with respect to web process-direction, on asecond conveyor to form a stack stream.
 100. The method of claim 66wherein packaging each registered stack in the stack stream to form abundle of printed sheets comprises banding, overwrapping,shrink-wrapping, or combinations thereof.
 101. The method of claim 66wherein packaging is accomplished by banding each registered stack. 102.The method of claim 66 wherein packaging is accomplished by placing twoor more bands around each registered stack.
 103. The method of claim 66wherein packaging is accomplished by placing one band around eachregistered stack.
 104. The method of claim 66 wherein packaging isaccomplished by over-wrapping each registered stack, banded orun-banded, to form a wrapped stack.
 105. The method of claim 104 whereinthe over-wrapping of each registered stack forms a sealed enclosureabout the stack.
 106. The method of claim 66 wherein packaging comprisesa first banding, a second over-wrapping, and optionally shrinking theover-wrapping.
 107. The method of claim 66 wherein packaging comprisesapplying a band to each stack, placing one or more banded stacks in acontainer, and sealing the container.
 108. The method of claim 107wherein the container is a box.
 109. The method of claim 108 wherein thecontainer has a sealable liner.
 110. The method of claim 66 wherein theprinted sheets are labels, business cards, credit cards, phone cards,greeting cards, trading cards, tickets, game cards, note pad sheets,currency, checks, negotiable instruments, interlaced images, coupons,chits, ballots, forms, time sheets, or combinations thereof.
 111. Themethod of claim 66 wherein the waste matrix is removed by vacuum anddiscarded.
 112. The method of claim 66 further comprising applying acoating to the first face, the second face, or both faces of the printedweb.
 113. The method of claim 112 wherein the coating is applied to theprinted side of the web, the unprinted side of the web, or both theunprinted side of the web and the printed side of the web.
 114. Themethod of claim 112 wherein the coating is a varnish, a gloss coat, aclear coat, a seal coat, an antistatic treatment, or combinationsthereof.
 115. The method of claim 112 further comprising chilling thecoated web.
 116. The method of claim 66 further comprising a web guidingsystem for web substrate regulation.
 117. The method of claim 66 furthercomprising monitoring the print quality of the printing.
 118. The methodof claim 117 wherein monitoring the print quality is accomplished with avideo inspection system.
 119. The method of claim 66 further comprisingmonitoring the registration of the printing to the cutting.
 120. Themethod of claim 119 wherein monitoring the registration of the printingto the cutting is accomplished by continuously detecting a referencemark on the matrix prior to cutting, and continuously adjusting, asneeded, the web position relative to the cutter to achieve apredetermined alignment of the cutter relative to the printed items onthe printed web.
 121. The method of claim 120 wherein continuouslyadjusting the web position relative to the cutter comprises controllablyvarying the speed of the web, controllably varying the position of theweb, or combinations thereof.
 122. The method of claim 120 whereinmonitoring the print registration is accomplished with a video printregistration inspection system.
 123. The method of claim 66 furthercomprising monitoring the color quality of the printing.
 124. The methodof claim 123 wherein monitoring the color quality is accomplished with aclosed-loop color control and adjustment system.
 125. The method ofclaim 124 further comprising adjusting print density to maintain thecolor quality of the printing.
 126. The method of claim 66 furthercomprising monitoring the cut precision of the cutting.
 127. The methodof claim 126 wherein monitoring the cut precision is accomplished with avideo inspection system.
 128. The method of claim 66 wherein the bundledprinted sheets are produced in from about 1 to about 4 minutes.
 130. Themethod of claim 66 further comprising placing a plurality of bundledprinted sheets in a container.
 131. The method of claim 130 furthercomprising sealing the container containing the plurality of bundledprinted sheets.
 132. The method of claim 131 further comprising placingthe sealed container on a carrier.
 133. The method of claim 66 furthercomprising removing debris after cutting the printed web into printedsheets.
 134. The method of claim 133 wherein removing debris aftercutting is accomplished with a vacuum, a brush disturber, atacky-surface member, or combinations thereof, situated in an area nearthe cutter.
 135. The method of claim 66 wherein the bundled printedsheets are free of a chipboard support or a stiffener panel.
 136. Themethod of claim 66 wherein the print registration to cut edges of theprinted sheets is within less than or equal to about plus or minus 0.03inches.
 137. The method of claim 66 wherein the method is accomplishedin ambient humidity of from about 65 to about 75 percent.
 138. Themethod of claim 66 wherein the cutting, collating, conveying, orpackaging is accomplished at an ambient temperature of from about 50 toabout 90 degrees ° C.
 139. The method of claim 66 further comprisingcontrolling or eliminating static during substrate transport, printing,cutting, collating, conveying, or combinations thereof.
 140. A method ofmaking bundled printed sheets, comprising: printing on a printable web;die-cutting the printed web into a stream of printed sheets and a wastematrix; collating each stream of printed sheets into a verticalregistered stack; conveying each registered stack into a single stackstream; banding each registered stack in the conveyed single stackstream to form a banded stack of bundled printed sheets wherein a bandcircumscribes a portion of two opposite sides and the entire height ofthe vertical stack, and a portion of the width of the first sheet and aportion of the width of the last sheet in the stack; overwrapping eachbanded stack; and optionally placing each overwrapped banded stack in acontainer.
 141. A method of making bundled printed sheets, comprising:providing single-sheets; optionally printing on the single-sheets with aprint engine; cutting each single-sheet into a stream of cut-printedsheets and a waste matrix; collating each stream of cut-printed sheetsinto a registered stack; conveying each registered stack into a stackstream; and packaging each registered stack in the stack stream into abundle of printed sheets.
 142. The method of claim 141 wherein providingsingle-sheets provides single-sheets free of printed images.
 143. Themethod of claim 141 wherein providing single-sheets providessingle-sheets having printed images on one or both sides of the sheet.144. The method of claim 141 wherein cutting is accomplished by anangle-cut rotary die-cutter.
 145. The method of claim 141 whereincutting comprises slit-and-gap cutting.
 146. The method of claim 141wherein collating is accomplished with a batch stacker machine modifiedto transport and receive a plurality of printed sheet streams.
 147. Themethod of claim 141 wherein collating is accomplished with a vacuumassist transfer device to transport the printed sheet streams to thecollator.
 148. The method of claim 141 further comprising controlling oreliminating static during cutting, collating, conveying, or combinationsthereof.
 149. A method of affixing printed sheets to articles,comprising: optionally slitting the over-wrapper on an over-wrappedbundle of printed sheets; removing the over-wrapper from theover-wrapped bundle of printed sheets comprising: a plurality of printedsheets in a stack; a band around the stack; and an overwrapper on thebanded stack, each printed sheet having a cut-to-print registrationvariance of from less than or equal to about {fraction (1/16)}^(th)inch, and each printed sheet having the same length and width dimensionsas the other printed sheets in the stack to within a variance of lessthan or equal to about {fraction (1/100)}^(th) inch; optionally fanningthe unwrapped bundle of printed sheets; removing the banding from theunwrapped bundle of printed sheets; inserting the stacked printed sheetsinto a sheet applicator machine; optionally activating an adhesive on,or applying an adhesive to, a portion of the individual printed sheets;and contacting the individual printed sheets having adhesive with anarticle.
 150. The method of claim 149 wherein the printed sheets arelabels.
 151. The method of claim 149 wherein the article is a containeror package.
 152. A stack of printed sheets, comprising: a plurality ofprinted sheets in a unitary form, each printed sheet having acut-to-print registration variance of from less than or equal to about{fraction (1/16)}^(th) inch, and each printed sheet having substantiallythe same length and width dimensions as the other printed sheets in thestack to within a variance of less than or equal to about {fraction(1/100)}^(th) inch, and the stack being in a label applicator machine.153. The stack of printed sheets of claim 152 wherein the unitary formis a stack of substantially identically shaped sheets.
 154. The stack ofprinted sheets of claim 152 wherein the unitary form is a cube orparallelepiped.
 155. The stack of printed sheets of claim 152 whereinthe unitary form is a stack of substantially identically irregularlyshaped sheets.
 156. The stack of printed sheets of claim 152 wherein theprinted sheets are labels.
 157. An article having a printed sheetattached thereto, the printed sheet being obtained from unpackaging abundle of substantially identically shaped printed sheets, the bundle ofprinted sheets comprising: a plurality of printed sheets in a stack; aband around the stack; and an overwrapper on the banded stack, eachprinted sheet having a narrow cut-to-print registration variance of fromless than or equal to about {fraction (1/16)}^(th) inch, and eachprinted sheet having the same length and width dimensions as the otherprinted sheets in the stack to within a narrow variance of less than orequal to about {fraction (1/100)}^(th) inch.
 158. An apparatus formaking bundled printed sheets comprising: a printable web; a printmodule to print on the printable web; a cutter module to cut the printedweb into a stream of printed sheets and a waste matrix; a collatormodule to collate each stream of printed sheets into a registered stack;a conveyor module to convey each registered stack into a stack stream;and a packaging module to package each registered stack in the stackstream into a package containing bundled printed sheets, wherein: theprintable web and the print module is a high speed lithographic pressadapted to: print and cure multiple color UV curable inks on a papersubstrate; apply a protective coating; chill the protectively coatedweb; and apply an antistatic coating; the cutter module is a rotarydie-cutter adapted to angle-cut the printed web, the cutter furtherincluding a static eliminator to facilitate separation of cut sheets andmatrix from one another and the cutter; the collator module is a sheetstream transporter and batch-stacker to transport and collate eachstream of printed sheets from the cutter module into a registered stack;the conveyor module is a conveyor for the output of each batch-stackerand adapted to directly receive the stack batch and transport the stackbatch as a single stack stream to the packaging module; each bundle ofprinted sheets having from about 10 to about 1,500 cut printed sheets,each printed sheet having a cut-to-print registration variance of fromless than or equal to about {fraction (1/16)}^(th) inch, and eachprinted sheet having the same length and width dimensions as the otherprinted sheets in the bundle to within a variance of less than or equalto about {fraction (1/100)}^(th) inch; the packaging module having abanding machine, an overwrapping machine, a heat-shrink machine, acontainerizer machine, a stretch banding machine, a palletizer, orcombinations thereof; and the apparatus having a humidity controller, aweb-nip just before the chiller module, and a web-nip just before thecutter module.
 159. A bundle of printed sheets, comprising: a pluralityof printed sheets in a stack; a band around the stack; and an optionaloverwrapper on the banded stack, each printed sheet having acut-to-print registration variance of from less than or equal to about{fraction (1/16)}^(th) inch, and each printed sheet having the samelength and width dimensions as the other printed sheets in the stack towithin a variance of less than or equal to about {fraction (1/100)}^(th)inch.
 160. A bundle of printed sheets, comprising: a plurality ofprinted sheets in a stack; a band around the stack; and an optionaloverwrapper on the banded stack, each printed sheet having acut-to-print registration variance of from less than or equal to about{fraction (3/64)}^(th) inch, and each printed sheet having the samelength and width dimensions as the other printed sheets in the stack towithin a variance of less than or equal to about {fraction (1/133)}^(rd)inch.
 161. The bundle of printed sheets of claim 159 wherein the printedsheets are labels, business cards, credit cards, phone cards, giftcards, greeting cards, trading cards, tickets, game cards, note padsheets, currency, checks, negotiable instruments, interlaced images,coupons, chits, ballots, forms, time sheets, or combinations thereof.162. The apparatus of claim 23 wherein a module comprises an inspectionstation.
 163. The apparatus of claim 23 wherein the print modulecomprises a print quality inspection system.
 164. The apparatus of claim23 wherein the print module comprises a print quality and printregistration inspection system and the cutter module comprises aprint-to-cut inspection system.
 166. The apparatus of claim 23 whereinthe conveyor module comprises a first conveyor having two over-underparallel endless belts and an elevator, wherein the two over-underparallel endless belts each carry a stack stream from the collator tothe second conveyor, the elevator being operable to alternate theposition of the two over-under parallel endless belts relative to thecollator and a second conveyor.
 165. The apparatus of claim 23 whereinthe cutter module comprises: a rotary die-cutter; an edge slitter forbursting; an air knife debris disturber; an abrader; and a debrisremoval device.
 166. The apparatus of claim 57 wherein the cut-to-printregistration variance is from less than or equal to about {fraction(3/64)}^(th) inch, and length and width dimensional variance is lessthan or equal to about {fraction (1/133)}^(rd) inch.
 167. The apparatusof claim 57 wherein the cut-to-print registration variance is from lessthan or equal to about 0.03 inches, and length and width dimensionalvariance is less than or equal to about 0.005 inches.
 168. The apparatusof claim 149 wherein the cut-to-print registration variance is from lessthan or equal to about {fraction (3/64)}^(th) inch, and length and widthdimensional variance is less than or equal to about {fraction(1/133)}^(rd) inch.
 169. The apparatus of claim 149 wherein thecut-to-print registration variance is from less than or equal to about0.03 inches, and length and width dimensional variance is less than orequal to about 0.005 inches.
 170. The apparatus of claim 152 wherein thecut-to-print registration variance is from less than or equal to about{fraction (3/64)}^(th) inch, and length and width dimensional varianceis less than or equal to about {fraction (1/133)}^(rd) inch.
 171. Theapparatus of claim 152 wherein the cut-to-print registration variance isfrom less than or equal to about 0.03 inches, and length and widthdimensional variance is less than or equal to about 0.005 inches. 172.The apparatus of claim 157 wherein the cut-to-print registrationvariance is from less than or equal to about {fraction (3/64)}^(th)inch, and length and width dimensional variance is less than or equal toabout {fraction (1/133)}^(rd) inch.
 173. The apparatus of claim 157wherein the cut-to-print registration variance is from less than orequal to about 0.03 inches, and length and width dimensional variance isless than or equal to about 0.005 inches.
 174. The apparatus of claim158 wherein the cut-to-print registration variance is from less than orequal to about {fraction (3/64)}^(th) inch, and length and widthdimensional variance is less than or equal to about {fraction(1/133)}^(rd) inch.
 175. The apparatus of claim 158 wherein thecut-to-print registration variance is from less than or equal to about0.03 inches, and length and width dimensional variance is less than orequal to about 0.005 inches.